Method Of Making Nonwoven Material Having Discrete Three-Dimensional Deformations With Wide Base Openings

ABSTRACT

A method of forming deformations in a nonwoven web includes the steps of: a) providing a precursor nonwoven web; b) providing a pair of forming members which include: a first forming member having a surface comprising a plurality of discrete, spaced apart male forming elements; and a second forming member having a surface comprising a plurality of recesses in the second forming member, wherein the recesses are aligned and configured to receive the male forming elements therein, wherein the recesses have a plan view periphery that is larger than, and may completely surround, the plan view periphery of the male elements; and c) mechanically deforming the precursor nonwoven web with the forming members by placing the precursor nonwoven web between the forming members. The method forms a nonwoven web having a generally planar first region and a plurality of discrete deformations. The deformations form protrusions that extend outward from the first surface of the nonwoven web and a base opening adjacent to the second surface of the nonwoven web. The maximum interior width of the cap portion of the protrusions is wider than the width of the base opening.

FIELD OF THE INVENTION

The present invention is directed to nonwoven materials having discretethree-dimensional deformations with wide base openings, methods ofmaking the same, and articles including such nonwoven materials.

BACKGROUND

Various materials for use in absorbent articles are disclosed in thepatent literature. Patent publications disclosing such materials andmethods for making the same include: U.S. Pat. No. 4,323,068, Aziz; U.S.Pat. No. 5,518,801, Chappell, et al.; U.S. Pat. No. 5,628,097, Benson,et al.; U.S. Pat. No. 5,804,021, Abuto, et al.; U.S. Pat. No. 6,440,564B1, McLain, et al.; U.S. Pat. No. 7,172,801, Hoying, et al.; U.S. Pat.No. 7,410,683, Curro, et al.; U.S. Pat. No. 7,553,532, Turner, et al.;U.S. Pat. No. 7,648,752 B2, Hoying, et al.; U.S. Pat. No. 7,682,686 B2,Curro, et al.; U.S. Pat. No. 8,241,543 B2, O'Donnell, et al.; U.S. Pat.No. 8,393,374 B2, Sato, et al.; U.S. Pat. No. 8,585,958 B2, Gray, etal.; U.S. Pat. No. 8,617,449 B2, Baker, et al.; U.S. Patent ApplicationPublications US 2006/0286343 A1; US 2010/0028621 A1; US 2010/0297377 A1;US 2012/0064298 A1; US 2013/0165883 A1; US 2014/0121621 A1; US2014/0121623 A1; US 2014/0121624 A1; US 2014/0121625 A1; US 2014/0121626A1; EP 1774940 B1; EP 1787611 B1; EP 1982013 B1; PCT WO 2008/146594 A1;and WO 2014/084066 A1 (Zuiko). Kao MERRIES™ diapers and Kimberly-ClarkHUGGIES® diapers have premium products in which a textured topsheet isbonded to another non-textured layer via heated embossing orhydroentangling.

A need exists for improved materials for use in absorbent articles, andmethods of making such materials. In certain cases, a need exists forimproved nonwoven materials or laminates of nonwoven materials that lookand feel soft, and have improved dryness. In particular, a need existsfor improved nonwoven materials having three-dimensional features formedtherein to provide improved softness and dryness, as well as a visualsignal of softness and dryness. The three dimensional features may formdepressions on one side of the material and protrusions on the opposingside. In some cases, it may be desirable to place such materials in anabsorbent article so that the depressions are visible on the topsheet ofthe absorbent article. In some of such cases, it is desirable for suchdepressions to be well-defined and have a wide opening formed thereby sothat they may not only improve liquid acquisition, but may also providea “signal” to the consumer of the liquid acquisition properties of anabsorbent article and ability to handle viscous fluids such as bowelmovements. It becomes increasingly more difficult to formthree-dimensional features that remain well-defined when making suchmaterials at high line speeds. In addition, in the event that thematerial is incorporated into a product (such as a disposable diaper)that is made or packaged under compression, it becomes difficult topreserve the three-dimensional character of the features/deformationsafter the material is subjected to such compressive forces. Certainprior three dimensional structures have a tendency to collapse or closeand become much less visible after compression. Further, a need existsfor materials that can be provided with such properties using mechanicaldeformation methods, which are less costly than higher energy processessuch as hydroentangling and hydro-molding.

Therefore, a need exists for such materials and high speed, relativelyinexpensive methods of making the same that have deformations thereinthat provide well-defined three-dimensional features, even after beingcompressed. A specific facet of high speed is the compatibility withmanufacturing lines for absorbent articles, which offers the advantagesof pattern flexibility and zoning, and reduces the need to ship bulkymaterials.

SUMMARY

The present invention is directed to nonwoven materials having discretethree-dimensional deformations with wide base openings, methods ofmaking the same, and articles including such nonwoven materials.

The nonwoven materials have deformations formed therein. Thedeformations form protrusions that extend outward from the first surfaceof the nonwoven material and a base opening inside the narrowest portionof the protrusion adjacent the second surface of the nonwoven material.The protrusions may comprise a cap portion. The maximum interior widthof the cap portion of the protrusions may be wider than the width of thebase opening. The protrusions may comprise fibers that extend from thebase of the protrusion to the distal end of the protrusions thatcontribute to form a portion of the sides and cap of the protrusion. Insome cases, multiple such fibers may be disposed substantiallycompletely around the sides of the protrusions. In some cases, whencompressive forces are applied on the nonwoven web, at least some of theprotrusions may be configured to collapse in a controlled manner suchthat the base opening may remain open. In some cases, the width of theprotrusions may vary along the length of the protrusions. In some cases,the nonwoven material comprises at least two layers, and the layers maydiffer in the concentration of fibers and/or the presence of thermalpoint bonds at various locations in and around the protrusions. In somecases, the deformations may have greater light transmission than theadjacent undeformed regions. Any of the properties described herein maybe present in the nonwoven materials separately, or in any combination.

The method of forming deformations in a nonwoven material includes thesteps of: a) providing at least one precursor nonwoven web; b) providinga pair of forming members which include: a first forming member having asurface comprising a plurality of discrete, spaced apart male formingelements; and a second forming member having a surface comprising aplurality of recesses in the second forming member, wherein the recessesare each aligned and configured to receive at least one of the maleforming elements therein, wherein the recesses may have a plan viewperiphery that is larger than, and may completely surround, the planview periphery of the male elements; and c) placing the precursornonwoven web between the forming members and mechanically deforming theprecursor nonwoven web with the forming members. The method forms anonwoven web having a generally planar first region and a plurality ofdiscrete deformations. The deformations form protrusions that extendoutward from the first surface of the nonwoven web and an opening in thesecond surface of the nonwoven web.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a photomicrograph showing the end view of a prior art tuft.

FIG. 2 is a schematic end view of a prior art tuft after it has beensubjected to compression.

FIG. 3 is a photomicrograph of the end of a prior art nonwoven webshowing a plurality of collapsed tufts.

FIG. 4 is a schematic side view of a prior art conical-shaped structurebefore and after it has been subjected to compression.

FIG. 5 is a plan view photomicrograph showing one side of the nonwovenmaterial having three-dimensional deformations formed therein, with theprotrusions oriented upward.

FIG. 6 is a plan view photomicrograph showing the other side of anonwoven material similar to that shown in FIG. 5, with the openings inthe nonwoven facing upward.

FIG. 7 is a Micro CT scan image showing a perspective view of aprotrusion in a single layer nonwoven material.

FIG. 8 is a Micro CT scan image showing a side of a protrusion in asingle layer nonwoven material.

FIG. 9 is a Micro CT scan image showing a perspective view of adeformation with the opening facing upward in a single layer nonwovenmaterial.

FIG. 10 is a perspective view of a deformation in a two layer nonwovenmaterial with the opening facing upward.

FIG. 11 is a photomicrograph of a cross-section taken along thetransverse axis of a deformation showing one example of a multi-layernonwoven material having a three-dimensional deformation in the form ofa protrusion on one side of the material that provides a wide opening onthe other side of the material, with the opening facing upward.

FIG. 12 is a schematic view of the protrusion shown in FIG. 11.

FIG. 13 is a plan view photomicrograph from the protrusion side of amaterial after it has been subjected to compression showing the highfiber concentration region around the perimeter of the protrusion.

FIG. 14 is a photomicrograph of the cross-section of a protrusion takenalong the transverse axis of the protrusion showing the protrusion afterit has been subjected to compression.

FIG. 15A is a cross-sectional view taken along the transverse axis of adeformation of one embodiment of a multi-layer nonwoven web shown withthe base opening facing upward.

FIG. 15B is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward.

FIG. 15C is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward.

FIG. 15D is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward.

FIG. 15E is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward.

FIG. 15F is a cross-sectional view taken along the transverse axis of adeformation of an alternative embodiment of a multi-layer nonwoven webshown with the base opening facing upward.

FIG. 16 is a plan view photomicrograph of a nonwoven web with theprotrusions oriented upward showing the concentration of fibers in onelayer of a two layer structure.

FIG. 17 is a perspective view photomicrograph showing the reduced fiberconcentration in the side walls of the protrusions in a layer similar tothat shown in FIG. 16.

FIG. 18 is a plan view photomicrograph of a nonwoven web with theprotrusions oriented upward showing the reduced concentration of fibersin the cap of a protrusion in the other layer (i.e. vs. the layer shownin FIG. 16) of a two layer structure.

FIG. 19 is a perspective view photomicrograph showing the decreasedfiber concentration in the side walls of the protrusions in a layersimilar to that shown in FIG. 18.

FIG. 19A is a Micro CT scan image showing the side of a protrusion in asingle layer of nonwoven material with the protrusion oriented downward.

FIG. 19B is a Micro CT scan plan view image showing the base opening ofa deformation in a single layer of nonwoven material.

FIG. 20 is a perspective view photomicrograph of one layer of a multiplelayer nonwoven material on the surface of a forming roll showing the“hanging chads” that can be formed in one of the layers when somenonwoven precursor web materials are used.

FIG. 21 is a perspective view of one example of an apparatus for formingthe nonwoven material described herein.

FIG. 22 is an enlarged perspective view of a portion of the male rollshown in FIG. 21.

FIG. 22A is an enlarged schematic side view showing an example of asurface texture formed by knurling a forming member.

FIG. 22A is a schematic side view of a male element with tapered sidewalls.

FIG. 22B is a schematic side view of a male element with undercut sidewalls.

FIG. 22C is an enlarged perspective view of a portion of a male rollhaving an alternative configuration.

FIG. 22D is a schematic side view of a male element with a rounded top.

FIG. 22E is a magnified photograph of the top surface of a male elementthat has been roughened by sandblasting.

FIG. 22F is a magnified photograph of the top surface of a male elementthat has a relatively smooth surface formed by machining the same.

FIG. 22G is a schematic side view showing an example of macro textureand micro texture that can be created by knurling the surface of a maleor female forming member.

FIG. 23 is an enlarged perspective view showing the nip between therolls shown in FIG. 21.

FIG. 23A is a schematic side view of a recess in a female forming memberwith a rounded top edge or rim.

FIG. 23B is a photograph of a second forming member having a surfacethat has been roughened with diamond type knurling.

FIG. 24 is a schematic perspective view of one version of a method ofmaking nonwoven materials having deformations therein where twoprecursor materials are used, one of which is a continuous web and theother of which is in the form of discrete pieces.

FIG. 24A is a schematic side view of an apparatus for forming thenonwoven material in which the web wraps around one of the rolls beforeand after passing through the nip between the rolls.

FIG. 25 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer composite structure wherein thelength of the acquisition layer is less that the length of the topsheetwith some layers partially removed.

FIG. 26 is one transverse cross-section of the diaper of FIG. 25 takenalong line 26-26.

FIG. 27 is an alternative transverse cross-section of the diaper of FIG.25.

FIG. 28 is a schematic side view of an apparatus for forming thenonwoven material which includes an additional roll for tip bonding thelayers of a multiple layer nonwoven material.

FIG. 29 is a schematic cross-sectional view of a tip bonded protrusion(shown oriented downward) made by the apparatus shown in FIG. 28.

FIG. 30 is a schematic side view of an apparatus for tip bonding thedeformed nonwoven material to an additional layer.

FIG. 31 is a schematic perspective view of a portion of a deformednonwoven web protrusion tip bonded to an additional layer (only aportion of the additional layer is shown) made by the apparatus shown inFIG. 30.

FIG. 32 is a schematic side view of an apparatus for deforming thenonwoven material which includes an additional roll for base bonding thedeformed nonwoven material.

FIG. 33A is a plan view of a_base bonded nonwoven made by the apparatusshown in FIG. 32 (shown with the base opening oriented upward).

FIG. 33B is a schematic cross-sectional view of the base bonded nonwovenshown in FIG. 33A taken along line 33B-33B.

FIG. 34 is a plan view photomicrograph showing the bonds formed by theapparatus shown in FIG. 32.

FIG. 35 is a schematic side view of an apparatus for base bonding thedeformed nonwoven material to an additional layer.

FIG. 35A is an enlarged perspective view of a portion of one embodimentof a female roll having a plurality of discrete bonding elements on itssurface.

FIG. 35B is an enlarged perspective view of a portion of one embodimentof a female roll having continuous bonding elements on its surface.

FIG. 35C is a plan view of a portion of the surface of one embodiment ofa bonding roll with a plurality of discrete bonding elements thereon.

FIG. 36 is a schematic perspective view of a portion of a deformednonwoven web that is base bonded to an additional layer (only a portionof the additional layer is shown) made by the apparatus shown in FIG.35.

FIG. 37 is a plan view photograph of a nonwoven material as describedherein with the base openings oriented upward.

FIG. 38 is a plan view photograph of an apertured nonwoven material.

FIG. 39 is a plan view photograph of a currently marketed topsheet.

FIG. 40 is a schematic side view of an apparatus for deforming thenonwoven material which includes additional rolls for tip bonding andbase bonding the deformed nonwoven material.

FIG. 41 is a schematic side view of an apparatus for deforming thenonwoven material which includes additional rolls for tip bonding thedeformed nonwoven material and then base bonding the deformed nonwovenmaterial to an additional layer.

FIG. 42 is a schematic side view of an apparatus for deforming thenonwoven material which includes additional rolls for base bonding thedeformed nonwoven material and then tip bonding the deformed nonwovenmaterial to an additional layer.

The embodiment(s) of the nonwoven material, the articles, the method andthe apparatus(es) shown in the drawings are illustrative in nature andare not intended to be limiting of the invention defined by the claims.Moreover, the features of the invention will be more fully apparent andunderstood in view of the detailed description.

DETAILED DESCRIPTION I. Definitions

The term “absorbent article” includes disposable articles such assanitary napkins, panty liners, tampons, interlabial devices, wounddressings, diapers, adult incontinence articles, wipes, and the like. Atleast some of such absorbent articles are intended for the absorption ofbody liquids, such as menses or blood, vaginal discharges, urine, andfeces. Wipes may be used to absorb body liquids, or may be used forother purposes, such as for cleaning surfaces. Various absorbentarticles described above will typically comprise a liquid pervioustopsheet, a liquid impervious backsheet joined to the topsheet, and anabsorbent core between the topsheet and backsheet. The nonwoven materialdescribed herein can comprise at least part of other articles such asscouring pads, wet or dry-mop pads (such as SWIFFER® pads), and thelike.

The term “absorbent core”, as used herein, refers to the component ofthe absorbent article that is primarily responsible for storing liquids.As such, the absorbent core typically does not include the topsheet orbacksheet of the absorbent article.

The term “aperture”, as used herein, refers to a regular orsubstantially regularly-shaped hole that is intentionally formed andextends completely through a web or structure (that is, a through hole).The apertures can either be punched cleanly through the web so that thematerial surrounding the aperture lies in the same plane as the webprior to the formation of the aperture (a “two dimensional” aperture),or the holes can be formed such that at least some of the materialsurrounding the opening is pushed out of the plane of the web. In thelatter case, the apertures may resemble a depression with an aperturetherein, and may be referred to herein as a “three dimensional”aperture, a subset of apertures.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article, such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs.

The term “cross-machine direction” or “CD” means the path that isperpendicular to the machine direction in the plane of the web.

The term “deformable material”, as used herein, is a material which iscapable of changing its shape or density in response to applied stressesor strains.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember, it is meant that the distal (or radially outwardmost) ends ofthe forming elements are distinct or unconnected in all directions,including in the machine and cross-machine directions (even though basesof the forming elements may be formed into the same surface of a roll,for example).

The term “disposable” is used herein to describe absorbent articles andother products which are not intended to be laundered or otherwiserestored or reused as an absorbent article or product (i.e., they areintended to be discarded after use and, preferably, to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner).

The term “forming elements”, as used herein, refers to any elements onthe surface of a forming member that are capable of deforming a web.

The term “integral”, as used herein as in “integral extension” when usedto describe the protrusions, refers to fibers of the protrusions havingoriginated from the fibers of the precursor web(s). Thus, as usedherein, “integral” is to be distinguished from fibers introduced to oradded to a separate precursor web for the purpose of making theprotrusions.

The term “joined to” encompasses configurations in which an element isdirectly secured to another element by affixing the element directly tothe other element; configurations in which the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element; andconfigurations in which one element is integral with another element,i.e., one element is essentially part of the other element. The term“joined to” encompasses configurations in which an element is secured toanother element at selected locations, as well as configurations inwhich an element is completely secured to another element across theentire surface of one of the elements. The term “joined to” includes anyknown manner in which elements can be secured including, but not limitedto mechanical entanglement.

The term “machine direction” or “MD” means the path that material, suchas a web, follows through a manufacturing process.

The term “macroscopic”, as used herein, refers to structural features orelements that are readily visible and distinctly discernable to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches (30 cm). Conversely, the term“microscopic” refers to such features that are not readily visible anddistinctly discernable under such conditions.

The term “mechanically deforming”, as used herein, refers to processesin which a mechanical force is exerted upon a material in order topermanently deform the material.

The term “permanently deformed”, as used herein, refers to the state ofa deformable material whose shape or density has been permanentlyaltered in response to applied stresses or strains.

The terms “SELF” and “SELF′ing”, refer to Procter & Gamble technology inwhich SELF stands for Structural Elastic Like Film. While the processwas originally developed for deforming polymer film to have beneficialstructural characteristics, it has been found that the SELF′ing processcan be used to produce beneficial structures in other materials.Processes, apparatuses, and patterns produced via SELF are illustratedand described in U.S. Pat. Nos. 5,518,801; 5,691,035; 5,723,087;5,891,544; 5,916,663; 6,027,483; and 7,527,615 B2.

The term “tuft”, as used herein, refers to a particular type of featurethat may be formed from fibers in a nonwoven web. Tufts may have atunnel-like configuration which may be open at both of their ends.

The term “web” is used herein to refer to a material whose primarydimension is X-Y, i.e., along its length (or longitudinal direction) andwidth (or transverse direction). It should be understood that the term“web” is not necessarily limited to single layers or sheets of material.Thus the web can comprise laminates or combinations of several sheets ofthe requisite type of materials.

The term “Z-dimension” refers to the dimension orthogonal to the lengthand width of the web or article. The Z-dimension usually corresponds tothe thickness of the web or material. As used herein, the term “X-Ydimension” refers to the plane orthogonal to the thickness of the web ormaterial. The X-Y dimension usually corresponds to the length and width,respectively, of the web or material.

II. Nonwoven Materials

The present invention is directed to nonwoven materials having discretethree-dimensional deformations, which deformations provide protrusionson one side of the material, and openings on the other side of thenonwoven materials. Methods of making the nonwoven materials are alsodisclosed. The nonwoven materials can be used in absorbent articles andother articles.

As used herein, the term “nonwoven” refers to a web or material having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which lattertypes of fabrics do not typically have randomly oriented orsubstantially randomly-oriented fibers. Nonwoven webs will have amachine direction (MD) and a cross machine direction (CD) as is commonlyknown in the art of web manufacture. By “substantially randomlyoriented” is meant that, due to processing conditions of the precursorweb, there may be a higher amount of fibers oriented in the MD than theCD, or vice versa. For example, in spunbonding and meltblowing processescontinuous strands of fibers are deposited on a support moving in theMD. Despite attempts to make the orientation of the fibers of thespunbond or meltblown nonwoven web truly “random,” usually a slightlyhigher percentage of fibers are oriented in the MD as opposed to the CD.

Nonwoven webs and materials are often incorporated into products, suchas absorbent articles, at high manufacturing line speeds. Suchmanufacturing processes can apply compressive and shear forces on thenonwoven webs that may damage certain types of three-dimensionalfeatures that have been purposefully formed in such webs. In addition,in the event that the nonwoven material is incorporated into a product(such as a disposable diaper) that is made or packaged undercompression, it becomes difficult to preserve the three-dimensionalcharacter of some types of prior three-dimensional features after thematerial is subjected to such compressive forces.

For instance, FIGS. 1 and 2 show an example of a prior art nonwovenmaterial 10 with a tufted structure. The nonwoven material comprisestufts 12 formed from looped fibers 14 that form a tunnel-like structurehaving two ends 16. The tufts 12 extend outward from the plane of thenonwoven material in the Z-direction. The tunnel-like structure has awidth that is substantially the same from one end of the tuft to theopposing end. Often, such tufted structures will have holes or openings18 at both ends and an opening 20 at their base. Typically, the openings18 at the ends of the tufts are at the machine direction (MD) ends ofthe tufts. The openings 18 at the ends of the tufts can be a result ofthe process used to form the tufts. If the tufts 12 are formed byforming elements in the form of teeth with a relatively small tip andvertical leading and trailing edges that form a sharp point, theseleading and/or trailing edges may punch through the nonwoven web atleast one of the ends of the tufts. As a result, openings 18 may beformed at one or both ends of the tufts 12.

While such a nonwoven material 10 provides well-defined tufts 12, theopening 20 at the base of the tuft structure can be relatively narrowand difficult to see with the naked eye. In addition, as shown in FIG.2, the material of the tuft 12 surrounding this narrow base opening 20may tend to form a hinge 22, or pivot point if forces are exerted on thetuft. If the nonwoven is compressed (such as in the Z-direction), inmany cases, the tufts 12 can collapse to one side and close off theopening 20. Typically, a majority of the tufts in such a tufted materialwill collapse and close off the openings 20. FIG. 2 schematically showsan example of a tuft 12 after it has collapsed. In FIG. 2, the tuft 12has folded over to the left side. FIG. 3 is an image showing a nonwovenmaterial with several upwardly-oriented tufts, all of which have foldedover to the side. However, not all of the tufts 12 will collapse andfold over to the same side. Often, some tufts 12 will fold to one side,and some tufts will fold to the other side. As a result of the collapseof the tufts 12, the openings 20 at the base of the tufts can close up,become slit-like, and virtually disappear.

Prior art nonwoven materials with certain other types of threedimensional deformations, such as conical structures, can also besubject to collapse when compressed. As shown in FIG. 4, conicalstructures 24 will not necessarily fold over as will certain tuftedstructures when subjected to compressive forces F. However, conicalstructures 24 can be subject to collapse in that their relatively widebase opening 26 and smaller tip 28 causes the conical structure to pushback toward the plane of the nonwoven material, such as to theconfiguration designated 24A.

The nonwoven materials of at least some embodiments of the presentinvention described herein are intended to better preserve the structureof discrete three-dimensional features in the nonwoven materials aftercompression.

FIGS. 5-14 show examples of nonwoven materials 30 with three-dimensionaldeformations comprising protrusions 32 therein. The nonwoven materials30 have a first surface 34, a second surface 36, and a thickness Ttherebetween (the thickness being shown in FIG. 12). FIG. 5 shows thefirst surface 34 of a nonwoven material 30 with the protrusions 32 thatextend outward from the first surface 34 of the nonwoven materialoriented upward. FIG. 6 shows the second surface 36 of a nonwovenmaterial 30 such as that shown in FIG. 5, having three-dimensionaldeformations formed therein, with the protrusions oriented downward andthe base openings 44 oriented upward. FIG. 7 is a Micro CT scan imageshowing a perspective view of a protrusion 32. FIG. 8 is a Micro CT scanimage showing a side view of a protrusion 32 (of one of the longer sidesof the protrusion). FIG. 9 is a Micro CT scan image showing aperspective view of a deformation with the opening 44 facing upward. Thenonwoven materials 30 comprise a plurality of fibers 38 (shown in FIGS.7-11 and 14). As shown in FIGS. 7 and 9, in some cases, the nonwovenmaterial 30 may have a plurality of bonds 46 (such as thermal pointbonds) therein to hold the fibers 38 together. Any such bonds 46 aretypically present in the precursor material from which the nonwovenmaterials 30 are formed.

The protrusions 32 may, in some cases, be formed from looped fibers(which may be continuous) 38 that are pushed outward so that they extendout of the plane of the nonwoven web in the Z-direction. The protrusions32 will typically comprise more than one looped fiber. In some cases,the protrusions 32 may be formed from looped fibers and at least somebroken fibers. In addition, in the case of some types of nonwovenmaterials (such as carded materials, which are comprised of shorterfibers), the protrusions 32 may be formed from loops comprising multiplediscontinuous fibers. Multiple discontinuous fibers in the form of aloop are shown as layer 30A in FIGS. 15A-15F. The looped fibers may be:aligned (that is, oriented in substantially the same direction); not bealigned; or, the fibers may be aligned in some locations within theprotrusions 32, and not aligned in other parts of the protrusions.

In some cases, if male/female forming elements are used to form theprotrusions 32, and the female forming elements substantially surroundthe male forming elements, the fibers in at least part of theprotrusions 32 may remain substantially randomly oriented (rather thanaligned), similar to their orientation in the precursor web(s). Forexample, in some cases, the fibers may remain substantially randomlyoriented in the cap of the protrusions, but be more aligned in the sidewalls such that the fibers extend in the Z-direction from the base ofthe protrusions to the cap. In addition, if the precursor web comprisesa multi-layer nonwoven material, the alignment of fibers can varybetween layers, and can also vary between different portions of a givenprotrusion 32 within the same layer.

The nonwoven material 30 may comprise a generally planar first region 40and the three-dimensional deformations may comprise a plurality ofdiscrete integral second regions 42. The term “generally planar” is notmeant to imply any particular flatness, smoothness, or dimensionality.Thus, the first region 40 can include other features that provide thefirst region 40 with a topography. Such other features can include, butare not limited to small projections, raised network regions around thebase openings 44, and other types of features. Thus, the first region 40is generally planar when considered relative to the second regions 42.The first region 40 can have any suitable plan view configuration. Insome cases, the first region 40 is in the form of a continuousinter-connected network which comprises portions that surround each ofthe deformations.

The term “deformation”, as used herein, includes both the protrusions 32formed on one side of the nonwoven material and the base openings 44formed in the opposing side of the material. The base openings 44 aremost often not in the form of an aperture or a through-hole. The baseopenings 44 may instead appear as depressions. The base openings 44 canbe analogized to the opening of a bag. A bag has an opening thattypically does not pass completely through the bag. In the case of thepresent nonwoven materials 30, as shown in FIG. 10, the base openings 44open into the interior of the protrusions 32.

FIG. 11 shows one example of a multi-layer nonwoven material 30 having athree-dimensional deformation in the form of a protrusion 32 on one sideof the material that provides a wide base opening 44 on the other sideof the material. The dimensions of “wide” base openings are described infurther detail below. In this case, the base opening 44 is orientedupward in the figure. When there is more than one nonwoven layer, theindividual layers can be designated 30A, 30B, etc. The individual layers30A and 30B each have first and second surfaces, which can be designatedsimilarly to the first and second surfaces 34 and 36 of the nonwovenmaterial (e.g., 34A and 36A for the first and second surfaces of thefirst layer 30A; and, 34B and 36B for the first and second surfaces ofthe second layer 30B).

As shown in FIGS. 11 and 12, the protrusions 32 comprise: a base 50proximate the first surface 34 of the nonwoven material; an opposedenlarged distal portion or cap portion, or “cap” 52, that extends to adistal end 54; side walls (or “sides”) 56; an interior 58; and a pair ofends 60 (the latter being shown in FIG. 5). The “base” 50 of theprotrusions 32 comprises the narrowest portion of the protrusion whenviewed from one of the ends of the protrusion. The term “cap” does notimply any particular shape, other than it comprises the wider portion ofthe protrusion 32 that includes and is adjacent to the distal end 54 ofthe protrusion 32. The side walls 56 have an inside surface 56A and anoutside surface 56B. As shown in FIGS. 11 and 12, the side walls 56transition into, and may comprise part of the cap 52. Therefore, it isnot necessary to precisely define where the side walls 56 end and thecap 52 begins. The cap 52 will have a maximum interior width, W_(I),between the inside surfaces 56A of the opposing side walls 56. The cap52 will also have a maximum exterior width W between the outsidesurfaces 56B of the opposing side walls 56. The ends 60 of theprotrusions 32 are the portions of the protrusions that are spacedfurthest apart along the longitudinal axis, L, of the protrusions.

As shown in FIGS. 11 and 12, the narrowest portion of the protrusion 32defines the base opening 44. The base opening 44 has a width W_(O). Thebase opening 44 may be located (in the z-direction) between the planedefined by the second surface 36 of the material and the distal end 54of the protrusion. As shown in FIGS. 11 and 12, the nonwoven material 30may have an opening in the second surface 36 (the “second surfaceopening” 64) that transitions into the base opening 44 (and vice versa),and is the same size as, or larger than the base opening 44. The baseopening 44 will, however, generally be discussed more frequently hereinsince its size will often be more visually apparent to the consumer inthose embodiments where the nonwoven material 30 is placed in an articlewith the base openings 44 visible to the consumer. It should beunderstood that in certain embodiments, such as in some embodiments inwhich the base openings 44 face outward (for example, toward a consumerand away from the absorbent core in an absorbent article), it may bedesirable for the base openings 44 not to be covered and/or closed offby another web.

As shown in FIG. 12, the protrusions 32 have a depth D measured from thesecond surface 36 of the nonwoven web to the interior of the protrusionat the distal end 54 of the protrusions. The protrusions 32 have aheight H measured from the second surface 36 of the nonwoven web to thedistal end 54 of the protrusions. In most cases the height H of theprotrusions 32 will be greater than the thickness T of the first region40. The relationship between the various portions of the deformationsmay be such that as shown in FIG. 11, when viewed from the end, themaximum interior width W_(I) of the cap 52 of the protrusions is widerthan the width, W_(O), of the base opening 44.

The protrusions 32 may be of any suitable shape. Since the protrusions32 are three-dimensional, describing their shape depends on the anglefrom which they are viewed. When viewed from above (that is,perpendicular to the plane of the web, or plan view) such as in FIG. 5,suitable shapes include, but are not limited to: circular,diamond-shaped, rounded diamond-shaped, U.S. football-shaped,oval-shaped, clover-shaped, heart-shaped, triangle-shaped, tear-dropshaped, and elliptical-shaped. (The base openings 44 will typically havea shape similar to the plan view shape of the protrusions 32.) In othercases, the protrusions 32 (and base openings 44) may be non-circular.The protrusions 32 may have similar plan view dimensions in alldirections, or the protrusions may be longer in one dimension thananother. That is, the protrusions 32 may have different length and widthdimensions. If the protrusions 32 have a different length than width,the longer dimension will be referred to as the length of theprotrusions. The protrusions 32 may, thus, have a ratio of length towidth, or an aspect ratio. The aspect ratios can range from about 1:1 toabout 10:1.

As shown in FIG. 5, the protrusions 32 may have a width, W, that variesfrom one end 60 to the opposing end 60 when the protrusions are viewedin plan view. The width W may vary with the widest portion of theprotrusions in the middle of the protrusions, and the width of theprotrusions decreasing at the ends 60 of the protrusions. In othercases, the protrusions 32 could be wider at one or both ends 60 than inthe middle of the protrusions. In still other cases, protrusions 32 canbe formed that have substantially the same width from one end of theprotrusion to the other end of the protrusion. If the width of theprotrusions 32 varies along the length of the protrusions, the portionof the protrusion where the width is the greatest is used in determiningthe aspect ratio of the protrusions.

When the protrusions 32 have a length L that is greater than their widthW, the length of the protrusions may be oriented in any suitabledirection relative to the nonwoven material 30. For example, the lengthof the protrusions 32 (that is, the longitudinal axis, LA, of theprotrusions) may be oriented in the machine direction, the cross-machinedirection, or any desired orientation between the machine direction andthe cross-machine direction. The protrusions 32 also have a transverseaxis TA generally orthogonal to the longitudinal axis LA in the MD-CDplane. In the embodiment shown in FIGS. 5 and 6, the longitudinal axisLA is parallel to the MD. In some embodiments, all the spaced apartprotrusions 32 may have generally parallel longitudinal axes LA.

The protrusions 32 may have any suitable shape when viewed from theside. Suitable shapes include those in which there is a distal portionor “cap” with an enlarged dimension and a narrower portion at the basewhen viewed from at least one side. The term “cap” is analogous to thecap portion of a mushroom. (The cap does not need to resemble that ofany particular type of mushroom. In addition, the protrusions 32 may,but need not, have a mushroom-like stem portion.) In some cases, theprotrusions 32 may be referred to as having a bulbous shape when viewedfrom the end 60, such as in FIG. 11. The term “bulbous”, as used herein,is intended to refer to the configuration of the protrusions 32 ashaving a cap 52 with an enlarged dimension and a narrower portion at thebase when viewed from at least one side (particularly when viewing fromone of the shorter ends 60) of the protrusion 32. The term “bulbous” isnot limited to protrusions that have a circular or round plan viewconfiguration that is joined to a columnar portion. The bulbous shape,in the embodiment shown (where the longitudinal axis LA of thedeformations 32 is oriented in the machine direction), may be mostapparent if a section is taken along the transverse axis TA of thedeformation (that is, in the cross-machine direction). The bulbous shapemay be less apparent if the deformation is viewed along the length (orlongitudinal axis LA) of the deformation such as in FIG. 8.

The protrusions 32 may comprise fibers 38 that at least substantiallysurround the sides of the protrusions. This means that there aremultiple fibers that extend (e.g., in the Z-direction) from the base 50of the protrusions 32 to the distal end 54 of the protrusions, andcontribute to form a portion of the sides 56 and cap 52 of a protrusion.In some cases, the fibers may be substantially aligned with each otherin the Z-direction in the sides 56 of the protrusions 32. The phrase“substantially surround”, thus, does not require that each individualfiber be wrapped in the X-Y plane substantially or completely around thesides of the protrusions. If the fibers 38 are located completely aroundthe sides of the protrusions, this would mean that the fibers arelocated 360° around the protrusions. The protrusions 32 may be free oflarge openings at their ends 60, such as those openings 18 at theleading end and trailing end of the tufts shown in FIG. 1. In somecases, the protrusions 32 may have an opening at only one of their ends,such as at their trailing end. The protrusions 32 also differ fromembossed structures such as shown in FIG. 4. Embossed structurestypically do not have distal portions that are spaced perpendicularlyaway (that is, in the Z-direction) from their base that are wider thanportions that are adjacent to their base, as in the case of the cap 52on the present protrusions 32.

The protrusions 32 may have certain additional characteristics. As shownin FIGS. 11 and 12, the protrusions 32 may be substantially hollow. Asused herein, the term “substantially hollow” refers to structures whichthe protrusions 32 are substantially free of fibers in interior ofprotrusions. The term “substantially hollow”, does not, however, requirethat the interior of the protrusions must be completely free of fibers.Thus, there can be some fibers inside the protrusions. “Substantiallyhollow” protrusions are distinguishable from filled three-dimensionalstructures, such as those made by laying down fibers, such as byairlaying or carding fibers onto a forming structure with recessestherein.

The side walls 56 of the protrusions 32 can have any suitableconfiguration. The configuration of the side walls 56, when viewed fromthe end of the protrusion such as in FIG. 11, can be linear orcurvilinear, or the side walls can be formed by a combination of linearand curvilinear portions. The curvilinear portions can be concave,convex, or combinations of both. For example, the side walls 56 in theembodiment shown in FIG. 11 comprise portions that are curvilinearconcave inwardly near the base of the protrusions and convex outwardlynear the cap of the protrusions. The sidewalls 56 and the area aroundthe base opening 44 of the protrusions may, under 20× magnification,have a visibly significantly lower concentration of fibers per givenarea (which may be evidence of a lower basis weight or lower opacity)than the portions of the nonwoven in the unformed first region 40. Theprotrusions 32 may also have thinned fibers in the sidewalls 56. Thefiber thinning, if present, will be apparent in the form of neckedregions in the fibers 38 as seen in scanning electron microscope (SEM)images taken at 200× magnification. Thus, the fibers may have a firstcross-sectional area when they are in the undeformed nonwoven precursorweb, and a second cross-sectional area in the side walls 56 of theprotrusions 32 of the deformed nonwoven web, wherein the firstcross-sectional area is greater than the second cross-sectional area.The side walls 56 may also comprise some broken fibers as well. In someembodiments, the side walls 56 may comprise greater than or equal toabout 30%, alternatively greater than or equal to about 50% brokenfibers.

In some embodiments, the distal end 54 of the protrusions 32 may becomprised of original basis weight, non-thinned, and non-broken fibers.If the base opening 44 faces upward, the distal end 54 will be at thebottom of the depression that is formed by the protrusion. The distalend 54 will be free from apertures formed completely through the distalend. Thus, the nonwoven materials may be nonapertured. The term“apertures”, as used herein, refers to holes formed in the nonwovensafter the formation of the nonwovens, and does not include the porestypically present in nonwovens. The term “apertures” also does not referto irregular breaks (or interruptions) in the nonwoven material(s) suchas shown in FIGS. 15D-15F and FIG. 20 resulting from localized tearingof the material(s) during the process of forming deformations therein,which breaks may be due to variability in the precursor material(s). Thedistal end 54 may have relatively greater fiber concentration incomparison to the remaining portions of the structure that forms theprotrusions. The fiber concentration can be measured by viewing thesample under a microscope and counting the number of fibers within anarea. As described in greater detail below, however, if the nonwoven webis comprised of more than one layer, the concentration of fibers in thedifferent portions of the protrusions may vary between the differentlayers.

The protrusions 32 may be of any suitable size. The size of theprotrusions 32 can be described in terms of protrusion length, width,caliper, height, depth, cap size, and opening size. (Unless otherwisestated, the length L and width W of the protrusions are the exteriorlength and width of the cap 52 of the protrusions.) The dimensions ofthe protrusions and openings can be measured before and aftercompression (under either a pressure of 7 kPa or 35 KPa, whichever isspecified) in accordance with the Accelerated Compression Methoddescribed in the Test Methods section. The protrusions have a caliperthat is measured between the same points as the height H, but under a 2KPa load, in accordance with the Accelerated Compression Method. Alldimensions of the protrusions and openings other than caliper (that is,length, width, height, depth, cap size, and opening size) are measuredwithout pressure applied at the time of making the measurement using amicroscope at 20× magnification.

In some embodiments, the length of the cap 52 may be in a range fromabout 1.5 mm to about 10 mm. In some embodiments, the width of the cap(measured where the width is the greatest) may be in a range from about1.5 mm to about 5 mm. The cap portion of the protrusions may have a planview surface area of at least about 3 mm². In some embodiments, theprotrusions may have a pre-compression height H that is in a range fromabout 1 mm to about 10 mm, alternatively from about 1 mm to about 6 mm.In some embodiments, the protrusions may have a post-compression heightH that is in a range from about 0.5 mm to about 6 mm, alternatively fromabout 0.5 mm to about 1.5 mm. In some embodiments, the protrusions mayhave a depth D, in an uncompressed state that is in a range from about0.5 mm to about 9 mm, alternatively from about 0.5 mm to about 5 mm. Insome embodiments, the protrusions may have a depth D, after compressionthat is in a range from about 0.25 mm to about 5 mm, alternatively fromabout 0.25 mm to about 1 mm.

The nonwoven material 30 can comprise a composite of two or morenonwoven materials that are joined together. In such a case, the fibersand properties of the first layer will be designated accordingly (e.g.,the first layer is comprised of a first plurality of fibers), and thefibers and properties of the second and subsequent layers will bedesignated accordingly (e.g., the second layer is comprised of a secondplurality of fibers). In a two or more layer structure, there are anumber of possible configurations the layers may take following theformation of the deformations therein. These will often depend on theextensibility of the nonwoven materials used for the layers. It isdesirable that at least one of the layers have deformations which formprotrusions 32 as described herein in which, along at least onecross-section, the width of the cap 52 of the protrusions is greaterthan the width of the base opening 44 of the deformations. For example,in a two layer structure where one of the layers will serve as thetopsheet of an absorbent article and the other layer will serve as anunderlying layer (such as an acquisition layer), the layer that hasprotrusions therein may comprise the topsheet layer. The layer that mosttypically has a bulbous shape will be the one which is in contact withthe male forming member during the process of deforming the web. FIG.15A-FIG. 15E show different alternative embodiments of three-dimensionalprotrusions 32 in multiple layer materials.

In certain embodiments, such as shown in FIGS. 11, 12, and 15A,similar-shaped looped fibers may be formed in each layer of multiplelayer nonwoven materials, including in the layer 30A that is spacedfurthest from the discrete male forming elements during the process offorming the protrusions 32 therein, and in the layer 30B that is closestto the male forming elements during the process. In the protrusions 32,portions of one layer such as 30B may fit within the other layer, suchas 30A. These layers may be referred to as forming a “nested” structurein the protrusions 32. Formation of a nested structure may require theuse of two (or more) highly extensible nonwoven precursor webs. In thecase of two layer materials, nested structures may form two completeloops, or (as shown in some of the following drawing figures) twoincomplete loops of fibers.

As shown in FIG. 15A, a three-dimensional protrusion 32 comprisesprotrusions 32A formed in the first layer 30A and protrusions 32B formedin the second layer 30B. In one embodiment, the first layer 30A may beincorporated into an absorbent article as an acquisition layer, and thesecond layer 30B may be a topsheet, and the protrusions formed by thetwo layers may fit together (that is, are nested). In this embodiment,the protrusions 32A and 32B formed by the first and second layers 30Aand 30B fit closely together. The three-dimensional protrusion 32Acomprises a plurality of fibers 38A and the three-dimensional protrusion32B comprises a plurality of fibers 38B. The three-dimensionalprotrusion 32B is nested into the three-dimensional protrusion 32A. Inthe embodiment shown, the fibers 38A in the first layer 30A are shorterin length than the fibers 38B in the second layer 30B. In otherembodiments, the relative length of fibers in the layers may be thesame, or in the opposite relationship wherein the fibers in the firstlayer are longer than those in the second layer. In addition, in thisembodiment, and any of the other embodiments described herein, thenonwoven layers can be inverted when incorporated into an absorbentarticle, or other article, so that the protrusions 32 face upward (oroutward). In such a case, the material suitable for the topsheet will beused in layer 30A, and material suitable for the underlying layer willbe used in layer 30B.

FIG. 15B shows that the nonwoven layers need not be in a contactingrelationship within the entirety of the protrusion 32. Thus, theprotrusions 32A and 32B formed by the first and second layers 30A and30B may have different heights and/or widths. The two materials may havesubstantially the same shape in the protrusion 32 as shown in FIG. 15B(where one of the materials has the same the curvature as the other). Inother embodiments, however, the layers may have different shapes. Itshould be understood that FIG. 15B shows only one possible arrangementof layers, and that many other variations are possible, but that as inthe case of all the figures, it is not possible to provide a drawing ofevery possible variation.

As shown in FIG. 15C, one of the layers, such as first layer 30A (e.g.,an acquisition layer) may be ruptured in the area of thethree-dimensional protrusion 32. As shown in FIG. 15C, the protrusions32 are only formed in the second layer 30B (e.g., the topsheet) andextend through openings in the first layer 30A. That is, thethree-dimensional protrusion 32B in the second layer 30B interpenetratesthe ruptured first layer 30A. Such a structure may place the topsheet indirect contact an underlying distribution layer or absorbent core, whichmay lead to improved dryness. In such an embodiment, the layers are notconsidered to be “nested” in the area of the protrusion. (In the otherembodiments shown in FIGS. 15D-15F, the layers would still be consideredto be “nested”.) Such a structure may be formed if the material of thesecond layer 30B is much more extensible than the material of the firstlayer 30A. In such a case, the openings can be formed by locallyrupturing first precursor web by the process described in detail below.The ruptured layer may have any suitable configuration in the area ofthe protrusion 32. Rupture may involve a simple splitting open of firstprecursor web, such that the opening in the first layer 30A remains asimple two-dimensional aperture. However, for some materials, portionsof the first layer 30A can be deflected or urged out-of-plane (i.e., outof the plane of the first layer 30A) to form flaps 70. The form andstructure of any flaps is highly dependent upon the material propertiesof the first layer 30A. Flaps can have the general structure shown inFIG. 15C. In other embodiments, the flaps 70 can have a morevolcano-like structure, as if the protrusion 32B is erupting from theflaps.

Alternatively, as shown in FIGS. 15D-15F, one or both of the first layer30A and the second layer 30B may be interrupted (or have a breaktherein) in the area of the three-dimensional protrusion 32. FIGS. 15Dand 15E show that the three-dimensional protrusion 32A of the firstlayer 30A may have an interruption 72A therein. The three-dimensionalprotrusion 32B of the non-interrupted second layer 30B may coincide withand fit together with the three-dimensional protrusion 32A of theinterrupted first layer 30A. Alternatively, FIG. 15F shows an embodimentin which both the first and second layers 30A and 30B haveinterruptions, or breaks, therein (72A and 72B, respectively). In thiscase, the interruptions in the layers 30A and 30B are in differentlocations in the protrusion 32. FIGS. 15D-15F show unintentional randomor inconsistent breaks in the materials typically formed by random fiberbreakage, which are generally misaligned and can be in the first orsecond layer, but are not typically aligned and completely through bothlayers. Thus, there typically will not be an aperture formed completelythrough all of the layers at the distal end 54 of the protrusions 32.

For dual layer and other multiple layer structures, the basis weightdistribution (or the concentration of fibers) within the deformedmaterial 30, as well as the distribution of any thermal point bonds 46can be different between the layers. As used herein, the term “fiberconcentration” has a similar meaning as basis weight, but fiberconcentration refers to the number of fibers/given area, rather thang/area as in basis weight. In the case of bond sites 46, the fibers maybe melted which may increase the density of the material in the bondsites 46, but the number of fibers will typically be the same as beforemelting.

Some such dual and multiple layer nonwoven materials may be described interms of such differences between layers, without requiring one or moreof the other features described herein (such as characteristics of thecap portion; controlled collapse under compression; and varying width ofthe protrusions). Of course such dual and multiple layer nonwovenmaterials may have any of these other features.

In such dual and multiple layer nonwoven materials each of the layerscomprises a plurality of fibers, and in certain embodiments, theprotrusions 32 will be formed from fibers in each of the layers. Forexample, one of the layers, a first layer, may form the first surface 34of the nonwoven material 30, and one of the layers, a second layer, mayform the second surface 36 of the nonwoven material 30. A portion of thefibers in the first layer form part of: the first region 40, the sidewalls 56 of the protrusions, and the distal ends 54 of the protrusions32. A portion of the fibers in the second layer form part of: the firstregion 40, the side walls 56 of the protrusions, and the distal ends 54of the protrusions 32.

As shown in FIG. 16, the nonwoven layer in contact with the male formingelement (e.g., 30B) may have a large portion at the distal end 54B ofthe protrusion 32B with a similar basis weight to the original nonwoven(that is, to the first region 40). As shown in FIG. 17, the basis weightin the sidewalls 56B of the protrusion 32B and near the base opening 44may be lower than the basis weight of the first region 40 of thenonwoven layer and the distal end 54 of the protrusion 32B. As shown inFIG. 18, the nonwoven layer in contact with the female forming element(e.g., 30A) may, however, have significantly less basis weight in thecap 52A of the protrusion 32A than in the first region 40 of thenonwoven layer. As shown in FIG. 19, the sidewalls 56A of the protrusion32A may have less basis weight than the first region 40 of the nonwoven.FIGS. 19A and 19B show that the nonwoven layer 30A in contact with thefemale forming element may have a fiber concentration that is greatestin the first region 40 (at the upper part of the image in FIG. 19A) andlowest at the distal end 54 of the protrusion 32. The fiberconcentration in the side wall 56A, in this case, may be less than thatof the first region 40, but greater than that at the distal end 54 ofthe protrusion 32.

Forming deformations in the nonwoven material may also affect the bonds46 (thermal point bonds) within the layer (or layers). In someembodiments, the bonds 46 within the distal end 54 of the protrusions 32may remain intact (not be disrupted) by the deformation process thatformed the protrusions 32. In the side walls 56 of the protrusions 32,however, the bonds 46 originally present in the precursor web may bedisrupted. When it is said that the bonds 46 may be disrupted, this cantake several forms. The bonds 46 can be broken and leave remnants of abond. In other cases, such as where the nonwoven precursor material isunderbonded, the fibers can disentangle from a lightly formed bond site(similar to untying a bow), and the bond site will essentiallydisappear. In some cases, after the deformation process, the side walls56 of at least some of the protrusions 32 may be substantially free (orcompletely free) of thermal point bonds.

Numerous embodiments of dual layer and other multiple layer structuresare possible. For example, a nonwoven layer 30B such as that shown inFIGS. 16 and 17 could be oriented with its base openings facing upward,and could serve as a topsheet of a dual or multiple layer nonwovenstructure (with at least one other layer serving as an acquisitionlayer). In this embodiment, the bonds 46 within first region 40 ofnonwoven layer 30B and the distal end 54 of the protrusions 32 remainintact. In the side walls 56 of the protrusions 32, however, the bonds46 originally present in the precursor web are disrupted such that theside walls 56 are substantially free of thermal point bonds. Such atopsheet could be combined with an acquisition layer in which theconcentration of fibers within the layer 30A in the first region 40 andthe distal end 54 of the protrusions 32 is also greater than theconcentration of fibers in the side walls 56 of the protrusions 32.

In other embodiments, the acquisition layer 30A described in thepreceding paragraph may have thermal point bonds 46 within first region40 of nonwoven layer 30B and the distal end 54 of the protrusions 32that remain intact. In the side walls 56 of the protrusions 32, however,the bonds 46 originally present in the precursor web comprising theacquisition layer 30A are disrupted such that the side walls 56 of theacquisition layer 30A are substantially free of thermal point bonds. Inother cases, the thermal point bonds in the acquisition layer 30A at thetop of the protrusions 32 may also be disrupted so that the distal end54 of at least some of the protrusions are substantially or completelyfree of thermal point bonds.

In other embodiments, a dual layer or multiple layer structure maycomprise a topsheet and an acquisition layer that is oriented with itsbase openings facing upward in which the concentration of fibers at thedistal end 54 of each layer (relative to other portions of the layer)differs between layers. For example, in one embodiment, in the layerthat forms the topsheet (second layer), the concentration of fibers inthe first region and the distal ends of the protrusions are each greaterthan the concentration of fibers in the side walls of the protrusions.In the layer that forms the acquisition layer (first layer), theconcentration of fibers in the first region of the acquisition layer maybe greater than the concentration of fibers in the distal ends of theprotrusions. In a variation of this embodiment, the concentration offibers in the first region of the first layer (acquisition layer) isgreater than the concentration of fibers in the side walls of theprotrusions in the first layer, and the concentration of fibers in theside walls of the protrusions in the first layer is greater than theconcentration of fibers forming the distal ends of the protrusions inthe first layer. In some embodiments in which the first layer comprisesa spunbond nonwoven material (in which the precursor material hadthermal point bonds distributed substantially evenly throughout), aportion of the fibers that form the first region in the first layercomprise thermal point bonds, and the portion of the fibers in the firstlayer forming the side walls and distal ends of at least some of theprotrusions may be substantially free of thermal point bonds. In theseembodiments, in at least some of the protrusions, at least some of thefibers in the first layer may form a nest or circle around (that is,encircle) the perimeter of the protrusion at the transition between thewide wall and the base of the protrusion as shown in FIG. 19.

The base openings 44 can be of any suitable shape and size. The shape ofthe base opening 44 will typically be similar to, or the same as, theplan view shape of the corresponding protrusions 32. The base opening 44may have a width that is greater than about any of the followingdimensions before (and after compression): 0.5 mm, 0.7 mm, 0.8 mm, 0.9mm, 1 mm, or any 0.1 mm increment above 1 mm. The width of the baseopening 44 may be in a range that is from any of the foregoing amountsup to about 4 mm, or more. The base openings 44 may have a length thatranges from about 1.5 mm or less to about 10 mm, or more. The baseopenings 44 may have an aspect ratio that ranges from about 1:1 to 20:1,alternatively from about 1:1 to 10:1. Measurements of the dimensions ofthe base opening can be made on a photomicrograph. When the size of thewidth of the base opening 44 is specified herein, it will be appreciatedthat if the openings are not of uniform width in a particular direction,the width, W_(o), is measured at the widest portion as shown in FIG. 6.The nonwoven materials of the present invention and the method of makingthe same may create deformations with a wider opening than certain priorstructures which have a narrow base. This allows the base openings 44 tobe more visible to the naked eye. The width of the base opening 44 is ofinterest because, being the narrowest portion of the opening, it will bemost restrictive of the size of the opening. The deformations retaintheir wide base openings 44 after compression perpendicular to the planeof the first region 40.

The deformations may compress under load. In some cases, it may bedesirable that the load is low enough so that, if the nonwoven is wornagainst a wearer's body, with the deformations in contact with thewearer's body, the deformations will be soft and will not imprint theskin. This applies in cases where either the protrusions 32 or the baseopenings 44 are oriented so that they are in contact with the wearer'sbody. For example, it may be desirable for the deformations to compressunder pressures of 2 kPa or less. In other cases, it will not matter ifthe deformations imprint the wearer's skin. It may be desirable for atleast one of the protrusions 32 in the nonwoven material 30 to collapseor buckle in the controlled manner described below under the 7 kPa loadwhen tested in accordance with the Accelerated Compression Method in theTest Methods section below. Alternatively, at least some, or in othercases, a majority of the protrusions 32 may collapse in the controlledmanner described herein. Alternatively, substantially all of theprotrusions 32 may collapse in the controlled manner described herein.The ability of the protrusions 32 to collapse may also be measured undera load of 35 kPa. The 7 kPa and 35 kPa loads simulate manufacturing andcompression packaging conditions. Wear conditions can range from no orlimited pressure (if the wearer is not sitting on the absorbent article)up to 2 kPa, 7 kPa, or more.

The protrusions 32 may collapse in a controlled manner after compressionto maintain the wide opening 44 at the base. FIG. 13 shows the firstsurface 34 of a nonwoven material 30 according to the present inventionafter it has been subjected to compression. FIG. 14 is a side view of asingle downwardly-oriented protrusion 32 after it has been subjected tocompression. As shown in FIG. 13, when the protrusions 32 have beencompressed, there appears to be a higher concentration of fibers in theform of a ring of increased opacity 80 around the base opening 44. Whena compressive force is applied to the nonwoven materials, the side walls56 of the protrusions 32 may collapse in a more desirable/controlledmanner such that the side walls 56 become concave and fold into regionsof overlapping layers (such as into an s-shape/accordion-shape). Thering of increased opacity 80 represents folded layers of material. Inother words, the protrusions 32 may have a degree of dimensionalstability in the X-Y plane when a Z-direction force is applied to theprotrusions. It is not necessary that the collapsed configuration of theprotrusions 32 be symmetrical, only that the collapsed configurationprevent the protrusions 32 from flopping over or pushing back into theoriginal plane of the nonwoven, and significantly reducing the size ofthe base opening (for example, by 50% or more). For example, as shown inFIG. 14, the left side of the protrusion 32 can form a z-foldedstructure, and the right side of the protrusion does not, but stillappears, when viewed from above, to have higher opacity due to a degreeof overlapping of the material in the folded portion. Without wishing tobe bound to any particular theory, it is believed that the wide baseopening 44 and large cap 52 (greater than the width of the base opening44), combined with the lack of a pivot point, causes the protrusions 32to collapse in a controlled manner (prevents the protrusion 32 fromflopping over). Thus, the protrusions 32 are free of a hinge structurethat would otherwise permit them to fold to the side when compressed.The large cap 52 also prevents the protrusion 32 from pushing back intothe original plane of the nonwoven.

The deformations can be disposed in any suitable density across thesurface of the nonwoven material 30. The deformations may, for example,be present in a density of: from about 5 to about 100 deformations;alternatively from about 10 to about 50 deformations; alternatively fromabout 20 to about 40 deformations, in an area of 10 cm².

The deformations can be disposed in any suitable arrangement across theplane of the nonwoven material. Suitable arrangements include, but arenot limited to: staggered arrangements, and zones.

The nonwoven webs 30 described herein can comprise any suitablecomponent or components of an absorbent article. For example, thenonwoven webs can comprise the topsheet of an absorbent article, or asshown in FIG. 25, if the nonwoven web 30 comprises more than one layer,the nonwoven web can comprise a combined topsheet 84 and acquisitionlayer 86 of an absorbent article, such as diaper 82. The diaper 82 shownin FIGS. 25-27 also comprises an absorbent core 88, a backsheet 94, anda distribution layer 96. The nonwoven materials of the presentdisclosure may also form an outer cover of an absorbent article, such asbacksheet 94. The nonwoven webs 30 can be placed in an absorbent articlewith the deformations 31 in any suitable orientation. For example, theprotrusions 32 can be oriented up or down. In other words, theprotrusions 32 may be oriented toward the absorbent core 88 as shown inFIG. 26. Thus, for example, it may be desirable for the protrusions 32to point inward toward the absorbent core 88 in a diaper (that is, awayfrom the body-facing side and toward the garment-facing side), or otherabsorbent article. Alternatively, the protrusions 32 may be oriented sothat they extend away from the absorbent core of the absorbent articleas shown in FIG. 27. In still other embodiments, the nonwoven webs 30can be made so that they have some protrusions 32 that are orientedupward, and some that are oriented downward. Without wishing to be boundto any particular theory, it is believed that such a structure may beuseful in that the protrusions that are oriented upward can be moreeffective for cleaning the body from exudates, while the protrusionsthat are oriented downward can be more effective for absorption ofexudates into the absorbent core. Therefore, without being bound totheory, a combination of these two protrusion orientations will offeradvantage that the same product can fulfill the two functions.

A two or more layer nonwoven structure may provide fluid handlingbenefits. If the layers are integrated together, and the protrusions 32are oriented toward the absorbent core, they may also provide a drynessbenefit. It may be desirable, on the other hand, for the protrusions 32to point outward, away from the absorbent core in a pad for a wet or drymop to provide a cleaning benefit. In some embodiments, when thenonwoven web 30 is incorporated into an absorbent article, theunderlying layers can be either substantially, or completely free, oftow fibers. Suitable underlying layers that are free of tow fibers may,for example, comprise a layer or patch of cross-linked cellulose fibers.In some cases, it may be desirable that the nonwoven material 30 is notentangled with (that is, is free from entanglement with) another web.

The layers of the nonwoven structure (e.g., a topsheet and/oracquisition layer) may be colored. Color may be imparted to the webs inany suitable manner including, but not limited to by color pigmentation.The term “color pigmentation” encompasses any pigments suitable forimparting a non-white color to a web. This term therefore does notinclude “white” pigments such as TiO₂ which are typically added to thelayers of conventional absorbent articles to impart them with a whiteappearance. Pigments are usually dispersed in vehicles or substrates forapplication, as for instance in inks, paints, plastics or otherpolymeric materials. The pigments may for example be introduced in apolypropylene masterbatch. A masterbatch comprises a high concentrationof pigment and/or additives which are dispersed in a carrier mediumwhich can then be used to pigment or modify the virgin polymer materialinto a pigmented bicomponent nonwoven. An example of suitable coloredmasterbatch material that can be introduced is Pantone color 270 Sanylenviolet PP 42000634 ex Clariant, which is a PP resin with a highconcentration of violet pigment. Typically, the amount of pigmentsintroduced by weight of the webs may be of from 0.3%-2.5%.Alternatively, color may be imparted to the webs by way of impregnationof a colorant into the substrate. Colorants such as dyes, pigments, orcombinations may be impregnated in the formation of substrates such aspolymers, resins, or nonwovens. For example, the colorant may be addedto molten batch of polymer during fiber or filament formation.

Precursor Materials.

The nonwoven materials of the present invention can be made of anysuitable nonwoven materials (“precursor materials”). The nonwoven webscan be made from a single layer, or multiple layers (e.g., two or morelayers). If multiple layers are used, they can be comprised of the sametype of nonwoven material, or different types of nonwoven materials. Insome cases, the precursor materials may be free of any film layers.

The fibers of the nonwoven precursor material(s) can be made of anysuitable materials including, but not limited to natural materials,synthetic materials, and combinations thereof. Suitable naturalmaterials include, but are not limited to cellulose, cotton linters,bagasse, wool fibers, silk fibers, etc. Cellulose fibers can be providedin any suitable form, including but not limited to individual fibers,fluff pulp, drylap, liner board, etc. Suitable synthetic materialsinclude, but are not limited to nylon, rayon and polymeric materials.Suitable polymeric materials include, but are not limited to:polyethylene (PE), polyester, polyethylene terephthalate (PET),polypropylene (PP), and co-polyester. In some embodiments, however, thenonwoven precursor materials can be either substantially, or completelyfree, of one or more of these materials. For example, in someembodiments, the precursor materials may be substantially free ofcellulose, and/or exclude paper materials. In some embodiments, one ormore precursor materials can comprise up to 100% thermoplastic fibers.The fibers in some cases may, therefore, be substantially non-absorbent.In some embodiments, the nonwoven precursor materials can be eithersubstantially, or completely free, of tow fibers.

The precursor nonwoven materials can comprise any suitable types offibers. Suitable types of fibers include, but are not limited to:monocomponent, bicomponent, and/or biconstituent, non-round (e.g.,shaped fibers (including but not limited to fibers having a trilobalcross-section) and capillary channel fibers). The fibers can be of anysuitable size. The fibers may, for example, have major cross-sectionaldimensions (e.g., diameter for round fibers) ranging from 0.1-500microns. Fiber size can also be expressed in denier, which is a unit ofweight per length of fiber. The constituent fibers may, for example,range from about 0.1 denier to about 100 denier. The constituent fibersof the nonwoven precursor web(s) may also be a mixture of differentfiber types, differing in such features as chemistry (e.g., PE and PP),components (mono- and bi-), shape (i.e. capillary channel and round) andthe like.

The nonwoven precursor webs can be formed from many processes, such as,for example, air laying processes, wetlaid processes, meltblowingprocesses, spunbonding processes, and carding processes. The fibers inthe webs can then be bonded via spunlacing processes, hydroentangling,calendar bonding, through-air bonding and resin bonding. Some of suchindividual nonwoven webs may have bond sites 46 where the fibers arebonded together.

In the case of spunbond webs, the web may have a thermal point bond 46pattern that is not highly visible to the naked eye. For example, densethermal point bond patterns are equally and uniformly spaced aretypically not highly visible. After the material is processed throughthe mating male and female rolls, the thermal point bond pattern isstill not highly visible. Alternatively, the web may have a thermalpoint bond pattern that is highly visible to the naked eye. For example,thermal point bonds that are arranged into a macro-pattern, such as adiamond pattern, are more visible to the naked eye. After the materialis processed through the mating male and female rolls, the thermal pointbond pattern is still highly visible and can provide a secondary visibletexture element to the material.

The basis weight of nonwoven materials is usually expressed in grams persquare meter (gsm). The basis weight of a single layer nonwoven materialcan range from about 8 gsm to about 100 gsm, depending on the ultimateuse of the material 30. For example, the topsheet of atopsheet/acquisition layer laminate or composite may have a basis weightfrom about 8 to about 40 gsm, or from about 8 to about 30 gsm, or fromabout 8 to about 20 gsm. The acquisition layer may have a basis weightfrom about 10 to about 120 gsm, or from about 10 to about 100 gsm, orfrom about 10 to about 80 gsm. The basis weight of a multi-layermaterial is the combined basis weight of the constituent layers and anyother added components. The basis weight of multi-layer materials ofinterest herein can range from about 20 gsm to about 150 gsm, dependingon the ultimate use of the material 30. The nonwoven precursor webs mayhave a density that is between about 0.01 and about 0.4 g/cm³ measuredat 0.3 psi (2 kPa).

The precursor nonwoven webs may have certain desired characteristics.The precursor nonwoven web(s) each have a first surface, a secondsurface, and a thickness. The first and second surfaces of the precursornonwoven web(s) may be generally planar. It is typically desirable forthe precursor nonwoven web materials to have extensibility to enable thefibers to stretch and/or rearrange into the form of the protrusions. Ifthe nonwoven webs are comprised of two or more layers, it may bedesirable for all of the layers to be as extensible as possible.Extensibility is desirable in order to maintain at least some non-brokenfibers in the sidewalls around the perimeter of the protrusions. It maybe desirable for individual precursor webs, or at least one of thenonwovens within a multi-layer structure, to be capable of undergoing anapparent elongation (strain at the breaking force, where the breakingforce is equal to the peak force) of greater than or equal to about oneof the following amounts: 100% (that is double its unstretched length),110%, 120%, or 130% up to about 200%. It is also desirable for theprecursor nonwoven webs to be capable of undergoing plastic deformationto ensure that the structure of the deformations is “set” in place sothat the nonwoven web will not tend to recover or return to its priorconfiguration.

Materials that are not extensible enough (e.g., inextensible PP) mayform broken fibers around much of the perimeter of the deformation, andcreate more of a “hanging chad” 90 (i.e., the cap 52 of the protrusions32 may be at least partially broken from and separated from the rest ofthe protrusion (as shown in FIG. 20). The area on the sides of theprotrusion where the fibers are broken is designated with referencenumber 92. Materials such as that shown in FIG. 20 will not be suitablefor a single layer structure, and, if used, will typically be part of acomposite multi-layer structure in which another layer has protrusions32 as described herein.

When the fibers of a nonwoven web are not very extensible, it may bedesirable for the nonwoven to be underbonded as opposed to optimallybonded. A thermally bonded nonwoven web's tensile properties can bemodified by changing the bonding temperature. A web can be optimally orideally bonded, underbonded, or overbonded. Optimally or ideally bondedwebs are characterized by the highest breaking force and apparentelongation with a rapid decay in strength after reaching the breakingforce. Under strain, bond sites fail and a small amount of fibers pullout of the bond site. Thus, in an optimally bonded nonwoven, the fibers38 will stretch and break around the bond sites 46 when the nonwoven webis strained beyond a certain point. Often there is a small reduction infiber diameter in the area surrounding the thermal point bond sites 46.Underbonded webs have a lower breaking force and apparent elongationwhen compared to optimally bonded webs, with a slow decay in strengthafter reaching the breaking force. Under strain, some fibers will pullout from the thermal point bond sites 46. Thus, in an underbondednonwoven, at least some of the fibers 38 can be separated easily fromthe bond sites 46 to allow the fibers 38 to pull out of the bond sitesand rearrange when the material is strained. Overbonded webs also have alowered breaking force and elongation when compared to optimally bondedwebs, with a rapid decay in strength after reaching the breaking force.The bond sites look like films and result in complete bond site failureunder strain.

When the nonwoven web comprises two or more layers, the different layerscan have the same properties, or any suitable differences in propertiesrelative to each other. In one embodiment, the nonwoven web 30 cancomprise a two layer structure that is used in an absorbent article. Forconvenience, the precursor webs and the material into which they areformed will generally be referred to herein by the same referencenumbers. However, in some cases, for additional clarity the precursorweb may be designated as 30′. As described above, one of the layers, asecond layer 30B, can serve as the topsheet of the absorbent article,and the first layer 30A can be an underlying layer (or sub-layer) andserve as an acquisition layer. The acquisition layer 30A receivesliquids that pass through the topsheet and distributes them tounderlying absorbent layers. In such a case, the topsheet 30B may beless hydrophilic than sub-layer(s) 30A, which may lead to betterdewatering of the topsheet. In other embodiments, the topsheet can bemore hydrophilic than the sub-layer(s). In some cases, the pore size ofthe acquisition layer may be reduced, for example via using fibers withsmaller denier or via increasing the density of the acquisition layermaterial, to better dewater the pores of the topsheet.

The second nonwoven layer 30B that may serve as the topsheet can haveany suitable properties. Properties of interest for the second nonwovenlayer, when it serves as a topsheet, in addition to sufficientextensibility and plastic deformation may include uniformity andopacity. As used herein, “uniformity” refers to the macroscopicvariability in basis weight of a nonwoven web. As used, herein,“opacity” of nonwoven webs is a measure of the impenetrability of visuallight, and is used as visual determination of the relative fiber densityon a macroscopic scale. As used herein, “opacity” of the differentregions of a single nonwoven deformation is determined by taking aphotomicrograph at 20× magnification of the portion of the nonwovencontaining the deformation against a black background. Darker areasindicate relatively lower opacity (as well as lower basis weight andlower density) than white areas.

Several examples of nonwoven materials suitable for use as the secondnonwoven layer 30B include, but are not limited to: spunbondednonwovens; carded nonwovens; and other nonwovens with high extensibility(apparent elongation in the ranges set forth above) and sufficientplastic deformation to ensure the structure is set and does not havesignificant recovery. One suitable nonwoven material as a topsheet for atopsheet/acquisition layer composite structure may be an extensiblespunbonded nonwoven comprising polypropylene and polyethylene. Thefibers can comprise a blend of polypropylene and polyethylene, or theycan be bi-component fibers, such as a sheath-core fiber withpolyethylene on the sheath and polypropylene in the core of the fiber.Another suitable material is a bi-component fiber spunbonded nonwovencomprising fibers with a polyethylene sheath and apolyethylene/polypropylene blend core.

The first nonwoven layer 30A that may, for example, serve as theacquisition layer can have any suitable properties. Properties ofinterest for the first nonwoven layer, in addition to sufficientextensibility and plastic deformation may include uniformity andopacity. If the first nonwoven layer 30A serves as an acquisition layer,its fluid handling properties must also be appropriate for this purpose.Such properties may include: permeability, porosity, capillary pressure,caliper, as well as mechanical properties such as sufficient resistanceto compression and resiliency to maintain void volume. Suitable nonwovenmaterials for the first nonwoven layer when it serves as an acquisitionlayer include, but are not limited to: spunbonded nonwovens; through-airbonded (“TAB”) carded nonwoven materials; spunlace nonwovens;hydroentangled nonwovens; and, resin bonded carded nonwoven materials.Of course, the composite structure may be inverted and incorporated intoan article in which the first layer 30A serves as the topsheet and thesecond layer 30B serves as an acquisition layer. In such cases, theproperties and exemplary methods of the first and second layersdescribed herein may be interchanged.

The layers of a two or more layered nonwoven web structure can becombined together in any suitable manner. In some cases, the layers canbe unbonded to each other and held together autogenously (that is, byvirtue of the formation of deformations therein). For example, bothprecursor webs 30A and 30B contribute fibers to deformations in a“nested” relationship that joins the two precursor webs together,forming a multi-layer web without the use or need for adhesives orthermal bonding between the layers. In other embodiments, the layers canbe joined together by other mechanisms. If desired an adhesive betweenthe layers, ultrasonic bonding, chemical bonding, resin or powderbonding, thermal bonding, or bonding at discrete sites using acombination of heat and pressure can be selectively utilized to bondcertain regions or all of the precursor webs. In addition, the multiplelayers may be bonded during processing, for example, by carding onelayer of nonwoven onto a spunbond nonwoven and thermal point bonding thecombined layers. In some cases, certain types of bonding between layersmay be excluded. For example, the layers of the present structure may benon-hydroentangled together.

If adhesives are used, they can be applied in any suitable manner orpattern including, but not limited to: slots, spirals, spray, andcurtain coating. Adhesives can be applied in any suitable amount orbasis weight including, but not limited to between about 0.5 and about30 gsm, alternatively between about 2 and about 5 gsm. Examples ofadhesives could include hot melt adhesives, such as polyolefins andstyrene block copolymers.

A certain level of adhesive may reduce the level of fuzz on the surfaceof the nonwoven material even though there may be a high percentage ofbroken fibers as a result of the deformation process. Glued dual-layerlaminates produced as described herein are evaluated for fuzz. Themethod utilizes a Martindale Abrasion Tester, based upon ASTM D4966-98.After abrading the samples, they are graded on a scale of 1-10 based onthe degree of fiber pilling (1=no fiber pills; 10=large quantity andsize of fiber pills). The protrusions are oriented away from the abraderso the land area in between the depressions is the primary surfaceabraded. Even though the samples may have a significant amount of fiberbreakage (greater than 25%, sometimes greater than 50%) in the sidewalls of the protrusions/depressions, the fuzz value may be low (around2) for several different material combinations, as long as the layers donot delaminate during abrasion. Delamination is best prevented by gluebasis weight, for example a glue basis weight greater than 3 gsm, andglue coverage.

When the precursor nonwoven web comprises two or more layers, it may bedesirable for at least one of the layers to be continuous, such as inthe form of a web that is unwound from a roll. In some embodiments, eachof the layers can be continuous. In alternative embodiments, such asshown in FIG. 24, one or more of the layers can be continuous, and oneor more of the layers can have a discrete length. The layers may alsohave different widths. For example, in making a combined topsheet andacquisition layer for an absorbent article, the nonwoven layer that willserve as the topsheet may be a continuous web, and the nonwoven layerthat will serve as the acquisition layer may be fed into themanufacturing line in the form of discrete length (for example,rectangular, or other shaped) pieces that are placed on top of thecontinuous web. Such an acquisition layer may, for example, have alesser width than the topsheet layer. The layers may be combinedtogether as described above.

III. Methods of Making the Nonwoven Materials

The nonwoven materials are made by a method comprising the steps of: a)providing at least one precursor nonwoven web; b) providing an apparatuscomprising a pair of forming members comprising a first forming member(a “male” forming member) and a second forming member (a “female”forming member); and c) placing the precursor nonwoven web(s) betweenthe forming members and mechanically deforming the precursor nonwovenweb(s) with the forming members. The forming members have a machinedirection (MD) orientation and a cross-machine direction (CD)orientation.

The first and second forming members can be plates, rolls, belts, or anyother suitable types of forming members. In some embodiments, it may bedesirable to modify the apparatus for incrementally stretching a webdescribed in U.S. Pat. No. 8,021,591, Curro, et al. entitled “Method andApparatus for Incrementally Stretching a Web” by providing theactivation members described therein with the forming elements of thetype described herein. In the embodiment of the apparatus 100 shown inFIG. 21, the first and second forming members 102 and 104 are in theform of non-deformable, meshing, counter-rotating rolls that form a nip106 therebetween. The precursor web(s) is/are fed into the nip 106between the rolls 102 and 104. Although the space between the rolls 102and 104 is described herein as a nip, as discussed in greater detailbelow, in some cases, it may be desirable to avoid compressing theprecursor web(s) to the extent possible.

First Forming Member.

The first forming member (such as “male roll”) 102 has a surfacecomprising a plurality of first forming elements which comprisediscrete, spaced apart male forming elements 112. The male formingelements are spaced apart in the machine direction and in thecross-machine direction. The term “discrete” does not include continuousor non-discrete forming elements such as the ridges and grooves oncorrugated rolls (or “ring rolls”) which have ridges that may be spacedapart in one, but not both, of the machine direction and in thecross-machine direction.

As shown in FIG. 22, the male forming elements 112 have a base 116 thatis joined to (in this case is integral with) the first forming member102, a top 118 that is spaced away from the base, and side walls (or“sides”) 120 that extend between the base 116 and the top 118 of themale forming elements. The male elements 112 may also have a transitionportion or region 122 between the top 118 and the side walls 120. Themale elements 112 also have a plan view periphery, and a height H₁ (thelatter being measured from the base 116 to the top 118). The discreteelements on the male roll may have a top 118 with a relatively largesurface area (e.g., from about 1 mm to about 10 mm in width, and fromabout 1 mm to about 20 mm in length) for creating a wide deformation.The male elements 112 may, thus, have a plan view aspect ratio (ratio oflength to width) that ranges from about 1:1 to about 10:1. For thepurpose of determining the aspect ratio, the larger dimension of themale elements 112 will be consider the length, and the dimensionperpendicular thereto will be considered to be the width of the maleelement. The male elements 112 may have any suitable configuration.

The base 116 and the top 118 of the male elements 112 may have anysuitable plan view configuration, including but not limited to: arounded diamond configuration as shown in FIGS. 21 and 22, an Americanfootball-like shape, triangle, circle, clover, a heart-shape, teardrop,oval, or an elliptical shape. The configuration of the base 116 and theconfiguration of the top 118 of the male elements 112 may be in any ofthe following relationships to each other: the same, similar, ordifferent. The top 118 of the male elements 112 can be flat, rounded, orany configuration therebetween.

The side walls 120 of the male elements 112 may have any suitableconfiguration. The male elements 112 may have vertical side walls 120,or tapered side walls 120. By vertical side walls, it is meant that theside walls 120 have zero degree side wall angles relative to theperpendicular from the base 116 of the side wall. In other embodiments,as shown in FIG. 22A, the side walls 120 can be tapered inwardly towardthe center of the male forming elements 112 from the base 116 to the top118 so that the side walls 120 form an angle, A, greater than zero. Instill other embodiments, as shown in FIG. 22B, the male forming elements112 may have a wider top surface than base so that the side walls 120are angled outwardly away from the center of the male forming elements112 from the base 116 to the top 118 of the male elements 112 (that is,the side walls may be undercut). The side wall angle can be the same onall sides of the male elements 112. Alternatively, the male elements 112may have a different side wall angle on one or more of their sides. Forexample, the leading edge (or “LE”) and trailing edge (or “TE”) of themale elements (with respect to the machine direction) may have equalside wall angles, and the sides of the male elements may have equal sidewall angles, but the side wall angles of the LE and TE may be differentfrom the side wall angle of the sides. In certain embodiments, forexample, the side wall angle of the sides of the male elements 112 maybe vertical, and the side walls of the LE and TE may be slightlyundercut.

The transition region or “transition” 122 between the top 118 and theside walls 120 of the male elements 112 may also be of any suitableconfiguration. The transition 122 can be in the form of a sharp edge (asshown in FIG. 22C) in which case there is zero, or a minimal radiuswhere the side walls 120 and the top 118 of the male elements meet. Thatis, the transition 122 may be substantially angular, sharp,non-radiused, or non-rounded. In other embodiments, such as shown inFIG. 22, the transition 122 between the top 118 and the side walls 120of the male elements 112 can be radiused, or alternatively beveled.Suitable radiuses include, but are not limited to: zero (that is, thetransition forms a sharp edge), 0.01 inch (about 0.25 mm), 0.02 inch(about 0.5 mm), 0.03 inch (about 0.76 mm), 0.04 inch (about 1 mm) (orany 0.01 inch increment above 0.01 inch), up to a fully rounded maleelement as shown in FIG. 22D.

In some cases, it may be desired to roughen the surface of all, or aportion, of the male elements 112. The surface of the male elements 112can be roughened in any suitable manner. The surface of the maleelements 112 can be roughened, for example, by: media blasting (that is,roughened with shot or “shot blasted”); wet blasting (roughed with waterjets); plasma coating, machining, or knurling (i.e., pressure embossingof surface of first forming member); or combinations of the same. Theroughened configuration and characteristics of the male elements 112will depend on the type of process used to roughen the same. Theroughening will typically provide at least the top 118 of at least someof the male elements 112 with greater than or equal to two discretefirst surface texture elements protruding therefrom.

If a media or wet blasting process is used to roughen the surface of themale elements 112, such processes will typically form a plurality ofrandomly arranged pits 138 in the surface of the male elements 112 thatform discrete randomly arranged raised elements or “first surfacetexture elements” 140 therebetween. The surface of the male elements112, as shown in FIG. 22E, may resemble sandpaper. The surface of themale elements 112 may be described in terms of the fineness of the mediaused to roughen the same and/or the number of raised elements per area(such as per square inch). For example the surface of the male elements112 may be roughened by 80, 120 or 150 grit media. The roughened surfacecan be described using the Surface Texture Characterization methodoutlined below.

If knurling is used to roughen the surface of the male elements 112,this will typically be performed by contacting the first forming member102 with a rotating patterned roll made of a harder material than thatof the first forming member. As shown in FIG. 22G, knurling will resultin displacing material on the top surface 118 of the male elements 112to create a pattern of valleys 144 with raised areas 146 therebetween.Knurling may modify the surface of a female forming member in the sameor a similar manner. Such processes will typically form a macroscaletexture (valleys 144 and raised areas 146) on the top surface 118 of themale elements 112. Such a pattern may, for example, appear in plan viewas a plurality of diamond-shaped elements, diagonal lines, or straight(MD or CD) lines with a diametral pitch that may range, for example,from about 60 (coarse) to about 160 (extra fine). The macroscale texturecan be characterized using a microscope with, for example, a 60× fieldof view. The spacing or pitch P of the elements 144 and 146 may rangefrom about 0.5-about 2.0 mm. The height H₂ of the macroscale textureelements may range from about 0.1-about 2 mm, alternatively from about0.1-about 0.5 mm. In addition to creating a macroscale texture, theknurling process creates a microscale texture 148 on the top surfaces ofthe raised macroscale texture elements 146, which can be described usingthe Surface Texture Characterization method below.

As mentioned above, any suitable portion of the male elements 112 may beroughened. Suitable portions of the male elements that may be roughenedinclude: the top surface 118; the side walls 120; the transition region122 between the top surface and the side walls; or any combinations ofthe foregoing. For example, in some embodiments the top surface 118 andthe transition region 122 may both be roughened. In other embodiments,only the transition region 122 may be roughened. Often, the portion ofthe male elements 112 that can be roughened will be dependent on theprocess used to roughen the same.

The surfaces of several rolls textured using the techniques mentionedabove can be described using the Surface Texture Characterization methodset out below and contrasted to non-roughened surfaces. As shown in FIG.22F, non-roughened surfaces may comprise machining marks, such ascontinuous ridges and grooves, but they are very regular and have littleheight compared to the textured surfaces described herein. For the malerolls, analysis is made of the top surface 118 of the male elements 112and the transition region 122 between the top surface and the sidewalls. For a knurled female roll, the analysis is made on themicrotexture 148 that is on top of the macroscale raised textureelements 146. The data in Table 1 below includes information on varioussurface texture parameters, including Sq, Sxp, Str, and Vmp. Table 1shows the Sq of a microtextured surface may have a value >1.7 μm. The Sqmay be up to about 15 μm, or more. The Sxp of a microtextured surfacemay have a value >3.0 μm, and may be up to about 50 μm, or more. The Strof a microtextured surface may have a value >0.27 μm, and may be up toabout 1.0 μm. The Vmp of a microtextured surface may have a value >0.07mL/m², and may be up to about 1.1 mL/m², or more

TABLE 1 Surface Texture Characterization of Forming Members Sq Sxp VmpSurface (μm) (μm) Str (mL/m²) Non-Roughened Male Top surface - maleelement 1 1.41 2.32 0.12 0.04 Top surface - male element 2 1.51 2.590.15 0.05 Transition region 0.86 1.71 0.25 0.05 Media Blasted Male (150Grit) Top surface - male element 1 2.18 4.17 0.81 0.11 Top surface -male element 2 2.17 4.26 0.96 0.12 Transition region 2.27 4.18 0.80 0.11Media Blasted Male (120 Grit) Top surface - male element 1 3.82 6.760.92 0.18 Top surface - male element 2 3.85 6.59 0.89 0.18 Transitionregion 3.86 6.87 0.85 0.19 Knurled Female - Top of Knurl Top of knurl -sample area 1 9.35 26.52 0.43 0.88 Top of knurl - sample area 2 10.9928.31 0.31 1.07 Top of knurl - sample area 3 9.59 26.97 0.40 0.88

Numerous other embodiments of the male forming elements 112 arepossible. In other embodiments, the top 118 of the male elements 112 canbe of different shapes from those shown in the drawings. In otherembodiments, the male forming elements 112 can be disposed in otherorientations on the first forming member 102 rather than having theirlength oriented in the machine direction (including CD-orientations, andorientations between the MD and CD). The male forming elements 112 onthe first forming member 102 may, but need not, all have the sameconfiguration or properties. In certain embodiments, the first formingmember 102 can comprise some male forming elements 112 having oneconfiguration and/or properties, and other male forming elements 112having one or more different configurations and/or properties.

The method of making the nonwoven materials may be run with the firstforming member 102 and male elements 112 under any of the followingconditions: at room temperature; with a chilled first forming member 102and/or male elements 112; or with heated first forming member and/ormale elements. In some cases, it may be desired to avoid heating thefirst forming member 102 and/or male elements 112. It may be desirableto avoid heating the first forming member and/or the male elementsaltogether. Alternatively, it may be desirable to avoid heating thefirst forming member and/or the male elements to a temperature at orabove that which would cause the fibers of the nonwoven to fusetogether. In some cases, it may be desirable to avoid heating the firstforming member and/or the male elements to a temperature that is greaterthan or equal to any of the following temperatures: 130° C., 110° C.,60° C., or greater than 25° C.

Second Forming Member.

As shown in FIG. 21, the second forming member (such as “female roll”)104 has a surface 124 having a plurality of cavities or recesses 114therein. The recesses 114 are aligned and configured to receive the maleforming elements 112 therein. Thus, the male forming elements 112 matewith the recesses 114 so that a single male forming element 112 fitswithin the periphery of a single recess 114, and at least partiallywithin the recess 114 in the z-direction. The recesses 114 have a planview periphery 126 that is larger than the plan view periphery of themale elements 112. As a result, the recess 114 on the female roll maycompletely encompass the discrete male element 112 when the rolls 102and 104 are intermeshed. The recesses 114 have a depth D₁ shown in FIG.23. In some cases, the depth D₁ of the recesses may be greater than theheight H₁ of the male forming elements 112.

The recesses 114 have a plan view configuration, side walls 128, a topedge or rim 134 around the upper portion of the recess where the sidewalls 128 meet the surface 124 of the second forming member 104, and abottom edge 130 around the bottom 132 of the recesses where the sidewalls 128 meet the bottom 132 of the recesses.

The recesses 114 may have any suitable plan view configuration providedthat the recesses can receive the male elements 112 therein. Therecesses 114 may have a similar plan view configuration as the maleelements 112. In other cases, some or all of the recesses 114 may have adifferent plan view configuration from the male elements 112.

The side walls 128 of the recesses 114 may be oriented at any suitableangle. In some cases, the side walls 128 of the recesses may bevertical. In other cases, the side walls 128 of the recesses may beoriented at an angle. Typically, this will be an angle that is taperedinwardly from the top 134 of the recess 114 to the bottom 132 of therecess. The angle of the side walls 128 of the recesses can, in somecases, be the same as the angle of the side walls 120 of the maleelements 112. In other cases, the angle of the side walls 128 of therecesses can differ from the angle of the side walls 120 of the maleelements 112.

The top edge or rim 134 around the upper portion of the recess where theside walls 128 meet the surface 124 of the second forming member 104 mayhave any suitable configuration. The rim 134 can be in the form of asharp edge (as shown in FIG. 23) in which case there is zero, or aminimal radius where the side walls 128 of the recesses meet the surfaceof the second forming member 104. That is, the rim 134 may besubstantially angular, sharp, non-radiused, or non-rounded. In otherembodiments, such as shown in FIG. 23A, the rim 134 can be radiused, oralternatively beveled. Suitable radiuses include, but are not limitedto: zero (that is, form a sharp edge), 0.01 inch (about 0.25 mm), 0.02inch (about 0.5 mm), 0.03 inch (about 0.76 mm), 0.04 inch (about 1 mm)(or any 0.01 inch increment above 0.01 inch) up to a fully rounded landarea between some or all of the side walls 128 around each recess 114.The bottom edge 130 of the recesses 114 may be sharp or rounded.

In some cases, it may be desired to roughen the surface of all, or aportion, of the second forming member 104 and/or recesses 114 byproviding the same with a plurality of discrete second surface textureelements 142 thereon. The surface of the second forming member 104and/or recesses 114 can be roughened in any of the manners describedabove for roughening the surface of the male elements 112. This mayprovide the surface of the second forming member 104 and/or recesses 114with second surface texture elements 142 (and/or valleys 144, raisedareas 146, and microscale texture 148 as shown in FIG. 22G) having thesame or similar properties as the first surface texture elements 140 onthe male elements 112. Thus, the second surface texture elements 142 canbe distributed on the surface of the second forming member 104 in aregular pattern or a random pattern.

Any suitable portion of the second forming member 104 and/or recesses114 may be roughened. As shown in FIG. 23A, suitable portions of thesecond forming member 104 and/or recesses 114 that may be roughenedinclude: the surface 124 of the second forming member; the side walls128 of the recesses; the top edge or rim 134 around the upper portion ofthe recess 114 where the side walls 128 meet the surface 124 of thesecond forming member 104; or any combinations of the foregoing. Forexample, in some embodiments the top surface 124 and the rim 134 mayboth be roughened. In other embodiments, only the rims 134 of therecesses 114 may be roughened. Often, the portion of the second formingmember 104 and/or recesses 114 that can be roughened, as in the case ofthe male elements, will be dependent on the process used to roughen thesame. FIG. 23B is a photograph of a second forming member 104 having asurface 124 that has been roughened with diamond type knurling.

As discussed above, the recesses 114 may be deeper than the height H₁ ofthe male elements 112 so the nonwoven material is not nipped (orsqueezed) between the male and female rolls 102 and 104 to the extentpossible. However, it is understood that passing the precursor web(s)between two rolls with a relatively small space therebetween will likelyapply some shear and compressive forces to the web(s). The presentmethod, however, differs from some embossing processes in which the topof the male elements compress the material to be embossed against thebottom of the female elements, thereby increasing the density of theregion in which the material is compressed.

The depth of engagement (DOE) is a measure of the level of intermeshingof the forming members. As shown in FIG. 23, the DOE is measured fromthe top 118 of the male elements 112 to the (outermost) surface 124 ofthe female forming member 114 (e.g., the roll with recesses). The DOEshould be sufficiently high, when combined with extensible nonwovenmaterials, to create protrusions 32 having a distal portion or cap 52with a maximum width that is greater than the width of the base opening44. The DOE may, for example, range from at least about 1.5 mm, or less,to about 5 mm, or more. In certain embodiments, the DOE may be betweenabout 2.5 mm to about 5 mm, alternatively between about 3 mm and about 4mm. The formation of protrusions 32 having a distal portion with amaximum width that is greater than the width of the base opening 44 isbelieved to differ from most embossing processes in which theembossments typically take the configuration of the embossing elements,which have a base opening that is wider than the remainder of theembossments.

As shown in FIG. 23, there is a clearance, C, between the sides 120 ofthe male elements 112 and the sides (or side walls) 128 of the recesses114. The clearances and the DOE's are related such that largerclearances can permit higher DOE's to be used. The clearance, C, betweenthe male and female roll may be the same, or it may vary around theperimeter of the male element 112. For example, the forming members canbe designed so that there is less clearance between the sides of themale elements 112 and the adjacent side walls 128 of the recesses 114than there is between the side walls at the end of the male elements 112and the adjacent side walls of the recesses 114. In other cases, theforming members can be designed so that there is more clearance betweenthe sides 120 of the male elements 112 and the adjacent side walls 128of the recesses 114 than there is between the side walls at the end ofthe male elements 112 and the adjacent side walls of the recesses. Instill other cases, there could be more clearance between between theside wall on one side of a male element 112 and the adjacent side wallof the recess 114 than there is between the side wall on the opposingside of the same male element 112 and the adjacent side wall of therecess. For example, there can be a different clearance at each end of amale element 112; and/or a different clearance on each side of a maleelement 112. Clearances can range from about 0.005 inches (about 0.1 mm)to about 0.1 inches (about 2.5 mm).

Some of the aforementioned male element 112 configurations alone, or inconjunction with the second forming member 104 and/or recess 114configurations may provide additional advantages. This may be due to bygreater lock of the nonwoven material on the male elements 112, whichmay result in more uniform and controlled strain on the nonwovenprecursor material. This may produce more well-defined protrusions 32and a stronger visual signal for consumers, giving the appearance ofsoftness, absorbency, and/or dryness.

The precursor nonwoven web 30 is placed between the forming members 102and 104. The precursor nonwoven web can be placed between the formingmembers with either side of the precursor web (first surface 34 orsecond surface 36) facing the first forming member, male forming member102. For convenience of description, the second surface 36 of theprecursor nonwoven web will be described herein as being placed incontact with the first forming member 102. (Of course, in otherembodiments, the second surface 36 of the precursor nonwoven web can beplaced in contact with the second forming member 104.)

The precursor material is mechanically deformed with the forming members102 and 104 when a force is applied on the nonwoven web with the formingmembers 102 and 104. The force can be applied in any suitable manner. Ifthe forming members 102 and 104 are in the form of plates, the forcewill be applied when the plates are brought together. If the formingmembers 102 and 104 are in the form of counter-rotating rolls (or belts,or any combination of rolls and belts), the force will be applied whenthe precursor nonwoven web passes through the nip between thecounter-rotating elements. The force applied by the forming membersimpacts the precursor web and mechanically deforms the precursornonwoven web.

Numerous additional processing parameters are possible. If desired, theprecursor nonwoven web may be heated before it is placed between theforming members 102 and 104. If the precursor nonwoven web is amulti-layer structure, any layer or layers of the same can be heatedbefore the layers are combined. Alternatively, the entire multi-layernonwoven web can be heated before it is placed between the formingmembers 102 and 104. The precursor nonwoven web, or layer(s) of thesame, can be heated in any suitable manner including, but not limited tousing conductive heating (such as by bringing the web(s) in contact withheated rolls), or by convective heating (i.e., by passing the same undera hot air knife or through an oven). The heating should be non-targeted,and without the help of any agent. The first forming member 102 and/orsecond forming member 104 (or any suitable portion thereof) can also beheated. If desired, the web could be additionally, or alternatively,heated after it is mechanically deformed.

If the precursor material is fed between forming members comprisingcounter-rotating rolls, several processing parameters may be desirable.With regard to the speed at which the precursor web is fed between thecounter-rotating rolls, it may be desirable to overfeed the web (createa negative draw) going into the nip 106 between the rolls. The surfacespeed of the metering roll immediately upstream of the forming members102 and 104 may be between about 1 and 1.2 times the surface speed ofthe forming members 102 and 104. It may be desirable for the tension onthe precursor web immediately before forming members 102 and 104 to beless than about 5 lbs. force (about 22 N), alternatively less than about2 lbs. force (about 9 N) for a web width of 0.17 m. With regard to thespeed at which the deformed web 30 is removed from between thecounter-rotating rolls, it may be desirable to create a positive drawcoming out of the nip between the rolls. The surface speed of themetering roll immediately downstream of the forming members 102 and 104may be between about 1 and 1.2 times the surface speed of the formingmembers 102 and 104. It may be desirable for the tension on the webimmediately after the forming members 102 and 104 to be less than about5 lbs. force (about 22 N), alternatively less than about 2 lbs. force(about 9 N).

As shown in FIG. 24A, rather than feeding the precursor web 30′ into thenip 106 between the forming members 102 and 104 without the precursorweb 30′ contacting any portion of the forming members prior to or afterthe nip, it may be desirable for the web to pre-wrap the second formingmember 104 prior to entering the nip 106, and for the web 30 to postwrap second forming member 104 after passing through the nip.

The apparatus 100 for deforming the web can comprise multiple nips fordeforming portions of the web in the same location such as described inU.S. Patent Publication No. US 2012/0064298 A1, Orr, et al. For example,the apparatus may comprise a central roll and satellite rolls with equalDOE or progressively greater DOE with each successive roll. This canprovide benefits such as reducing damage to the web and/or helping tofurther ensure that the deformations are permanently set in the webthereby preventing the web from recovering toward its undeformedcondition.

The apparatus for deforming the web can also comprise belts, or othermechanisms, for holding down the longitudinal edges of the web toprevent the web from being drawn inward in the cross-machine direction.

When deforming multiple webs that are laminated together with anadhesive, it may be desirable to chill the forming members in order toavoid glue sticking to and fouling the forming members. The formingmembers can be chilled using processes know in the art. One such processcould be an industrial chiller that utilizes a coolant, such aspropylene glycol. In some cases, it may be desirable to operate theprocess in a humid environment such that a layer of condensate forms onthe forming members.

The apparatus 100 for deforming the web can be at any suitable locationin any suitable process. For example, the apparatus can be locatedin-line with a nonwoven web making process or a nonwoven laminate makingprocess. Alternatively, the apparatus 100 can be located in-line in anabsorbent article converting process (such as after the precursor web isunwound and before it is incorporated as part of the absorbent article).

The process forms a nonwoven web 30 comprising a generally planar firstregion 40 and a plurality of discrete integral second regions 42 thatcomprise deformations comprising protrusions 32 extending outward fromthe first surface 34 of the nonwoven web and openings in the secondsurface 36 of the nonwoven web. (Of course, if the second surface 36 ofthe precursor nonwoven web is placed in contact with the second formingmember 104, the protrusions will extend outward from the second surfaceof the nonwoven web and the openings will be formed in the first surfaceof the nonwoven web.) Without wishing to be bound by any particulartheory, it is believed that the extensibility of the precursor web (orat least one of the layers of the same) when pushed by the male formingelements 112 into the recesses 114 with depth of engagement DOE beingless than the depth D₁ of the recesses, stretches a portion of thenonwoven web to form a deformation comprising a protrusion with theenlarged cap and wide base opening described above. (This can beanalogized to sticking one's finger into an uninflated balloon tostretch and permanently deform the material of the balloon.)

In cases in which the precursor nonwoven material 30′ comprises morethan one layer, and one of the layers is in the form of discrete piecesof nonwoven material, as shown in FIG. 24, it may be desirable for thedeformations to be formed so that the base openings 44 are in thecontinuous layer (such as 30B) and the protrusions 32 extend toward thediscrete layer (such as 30A). Of course, in other embodiments, thedeformations in such a structure can be in the opposite orientation. Thedeformations can be distributed in any suitable manner over the surfacesof such continuous and discrete layers. For example, the deformationscan: be distributed over the full length and/or width of the continuouslayer; be distributed in an area narrower than the width of thecontinuous layer; or be limited to the area of the discrete layer.

The method of deforming the nonwoven materials described herein mayexclude (or be distinguishable from) the following processes:hydroforming (hydroentangling); hydromolding; use of air jets;rigid-to-resilient (e.g., steel/rubber) embossing; and the use of apatterned surface against a flat anvil surface (e.g., rigid-to-rigidembossing). The method may also exclude (or be distinguishable from) TheProcter & Gamble Company's processes for making Structural Elastic-LikeFilms (“SELF” processes). The forming members used herein differ fromthe forming members used in SELFing processes to form corrugatedstructures (and tufted structures) in that the SELF teeth typically havea comparatively small diameter tip, and the ridges of the mating ringroll only border the SELF teeth on the sides, and not the front and backof the teeth.

IV. Optional Processing Steps

The precursor web material 30′ and/or the nonwoven web material 30 withdeformations therein can be subjected to an optional additionalprocessing step. The additional steps can include, but are not limitedto embossing and/or bonding.

A. Embossing.

The precursor web material 30′ and/or the nonwoven web material 30 withdeformations therein can be subjected to an optional embossing step. Theprecursor web material 30′ can be embossed prior to the formation ofdeformations therein. In addition, or alternatively, the nonwoven webmaterials 30 described herein may be embossed after the formation ofdeformations (protrusions 32 and base openings 44) therein.

The embossments can be provided in any known manner. Suitable embossingmethods include, but are not limited to rigid-to-resilient andrigid-to-rigid methods described in the preceding section. If theprecursor nonwoven material or the nonwoven web materials 30 withdeformations therein are embossed, the embossments can be positioned ina specific location relative to the deformations. That is, theembossments may be registered with the deformations. In otherembodiments, the embossments may be randomly positioned relative to thedeformations.

B. Optional Bonding Steps.

1. Bonding Together Portions of a Deformed Nonwoven Material.

a) Tip Bonding of a Deformed Nonwoven Material.

One optional bonding step involves bonding portions of the deformednonwoven material 30 together at the tops or distal ends 54 of theprotrusions 32 (“tip bonding”). If the deformed nonwoven material 30 isa single layer material, then this step will bond the fibers in thelayer together at the distal ends 54 of the protrusions 32. If thedeformed nonwoven material 30 is a dual or multiple layer nonwovenmaterial, then this step will bond the fibers together at the distalends 54 of the protrusions 32 and will also bond fibers in each of thelayers together at the distal ends 54 of the protrusions 32.

FIG. 28 shows one embodiment of an apparatus 100 for deforming thenonwoven material which includes an additional bonding roll 150 for tipbonding the deformed nonwoven material 30. As shown in FIG. 28, aprecursor web 30′ is fed into the deforming nip 106 between firstforming roll 102 and second forming roll 104. After leaving thedeforming nip 106, the deformed web 30 is wrapped partially around thefirst forming roll, male roll 102. Vacuum, hold down belts, or someother mechanism could be used to keep the deformed web 30 seated on thefirst forming roll 102. While the web 30 is still in contact with themale roll 102, it passes through a second nip 156 between male roll 102and the additional bonding roll 150. The additional bonding roll 150 cancompress the fibers at the distal ends 54 of the protrusions 32sufficient to partially melt and bond the fibers at this locationtogether. The bonding roll 150 may be heated to help facilitate bonding.Alternatively, ultrasonics could be used to facilitate bonding. In thecase of at least some of the precursor materials described herein, thematerials can be bonded together if the bonding roll 150 surfacetemperature is between about 120° F. (about 50° C.) and about 270° F.(about 130° C.). Upon exit of the second nip 156, the web may wrap thebonding roll 150 as shown in FIG. 28, or it may wrap the male roll 102.

As shown in FIG. 29, this produces a protrusion 32 in which the layersare bonded together at the tops (or distal ends 54) of the protrusions32. This will form a tip bonded portion 152. The tip bonded portion 152(and the bonds formed in the other optional post bonding steps describedherein) will often differ in at least one of: size (that is, they may belarger), shape, and location from any thermal point bonds present inspunbonded nonwoven layers. The post deformation bond sites willtypically be registered with the deformations in the deformed nonwoven,while thermal point bonds are provided in a separate and differentpattern in a spunbonded precursor web. The bonding may result in a moretranslucent (film-like) bonded portion 152. Placing a layer containingcolor adjacent to the deformed material 30 could result in color showingthrough primarily in the translucent bonded portion 152, highlightingthe protrusion 32.

Without wishing to be bound by any particular theory, it is believedthat bonding the layers together at the distal ends 54 of theprotrusions 32 may provide benefits which include: 1) increasedperception of the depth of the base openings 44 when the base openingsare oriented toward the consumer, as well as 2) improved dryness (byreducing the hang-up of fluid in the bottoms of the protrusions when thebase openings 44 are oriented toward the consumer); and 3) reduction orelimination of the need to glue or otherwise bond the layers of a dualor multilayer precursor web together.

b) Base Bonding of a Deformed Nonwoven Material.

Another optional bonding step involves bonding portions of the deformednonwoven material 30 together at base bond sites in the undeformed firstregion 40 outside of the bases 50 of the protrusions 32 (“basebonding”). If the deformed nonwoven material 30 is a single layermaterial, then this step will bond the fibers of the layer together inthe undeformed first region 40 outside of the bases 50 of theprotrusions 32. If the deformed nonwoven material 30 is a dual ormultiple layer nonwoven material, then this step will bond the fiberstogether in the undeformed first region 40 outside of the bases of theprotrusions 32 and will also bond fibers in each of the layers togetherin the undeformed first region 40 outside of the bases of theprotrusions 32.

FIG. 32 shows one embodiment of an apparatus 100 for deforming thenonwoven material which includes an additional bonding roll 160 for basebonding the deformed nonwoven material 30. In FIG. 32, the position offirst and second forming rolls 102 and 104 are reversed and the femaleroll 104 is located on top of the male roll 102. However, in otherembodiments, the male roll 102 could be on top as shown in the tipbonding roll arrangements described above. A precursor nonwoven web 30′is fed into the deforming nip 106 between first forming roll 102 andsecond forming roll 104. After leaving the deforming nip 106, thedeformed web 30 is wrapped partially around the second forming roll,female roll 104. Vacuum, hold down belts, or some other mechanism couldbe used to keep the deformed web 30 seated on the second forming roll104. While the web 30 is still in contact with the female roll 104, itpasses through a second nip 166 between female roll 104 and theadditional bonding roll 160. The additional bonding roll 160 cancompress the fibers in the undeformed first region 40 outside of thebases 50 of the protrusions 32 sufficient to partially melt and bond thefibers at this location together. The bonding roll may be heated tofacilitate bonding in the case of at least some of the precursormaterials described herein. Ultrasonics may also be used to facilitatebonding. Upon exit of the second nip 166, the web may wrap the bondingroll 160 as shown in FIG. 32, or it may wrap the female roll 104.

There are a number of variations of the roll configurations in thebonding step. The surface of the bonding roll 160 may be substantiallysmooth. Alternatively, as shown in FIGS. 32 and 35C, it can have aplurality of discrete, spaced-apart bonding elements 162 protruding fromits surface. The portions of the surface 124 of the female roll 104 thatare located outside of the recesses 114 in the female roll 104 may alsobe substantially smooth, or they may have a plurality of discrete,spaced-apart bonding elements 164 protruding from the surface 124. Thebonding elements 164 on the surface 124 of the female roll 104 may bediscrete, spaced-apart bonding elements 164 as shown in FIG. 35A, orthey may be continuous bonding elements 164 as shown in FIG. 35B.

In those cases in which the surface of the bonding roll 160 issubstantially smooth, the base bond sites 168 may be at leastsubstantially continuous and may substantially or completely surroundthe deformations in the web 30. FIG. 33A shows a web having continuousbase bond sites 168. FIG. 33B is a cross-section of the web shown inFIG. 33A.

As shown in FIG. 34, in those cases in which the bonding roll 160 or thefemale roll 104 have a plurality of discrete, spaced-apart bondingelements 162 and 164, respectively, protruding from their surfaces, thebonding elements will only bond discrete, spaced-apart regions of theweb 30 in the undeformed first region 40 outside of the bases 50 of theprotrusions 32. In such case, the base bonds 168 may be located in atleast two discrete portions of the first region 40 which are adjacent toand lie outside of at least some of the deformations. In other words, insuch cases there may be at least two base bond sites 168 for a givendeformation.

c) Tip and Base Bonding.

In another embodiment, the deformed nonwoven material 30 can be both tipand base bonded. This can be done in a process that is a combination ofthe processes shown in FIGS. 28 and 32.

FIG. 40 shows one embodiment of an apparatus 100 for carrying out such aprocess. The rolls 102, 104, and 150 comprise the tip bonding portion ofthe apparatus, which is similar to the apparatus shown in FIG. 28. FIG.40 differs in that the precursor web 30′ is shown as being fed into thedeforming nip 106 from the right side in FIG. 40, instead of the leftside, and the deformed web 30 wraps around male roll 102 instead ofbonding roll 150 after it leaves the deforming nip 106. Therefore, thedescription of this portion of the apparatus will incorporate the abovedescription of the apparatus shown in FIG. 28, and will not be repeatedin its entirety herein.

The apparatus shown in FIG. 40 further comprises a second female roll104A and a base bonding roll 160. The male roll 102, the second femaleroll 104A, and the base bonding roll 160 comprise the base bondingportion of the apparatus, which is similar to the apparatus shown inFIG. 32. FIG. 40 differs in that the deformed bonded web 30 is shown aswrapping around the second female roll 104A as it leaves the apparatusin FIG. 40, instead of wrapping around the base bonding roll 160.Therefore, the description of this portion of the apparatus willincorporate the above description of the apparatus shown in FIG. 32, andwill not be repeated in its entirety herein.

As shown in FIG. 40, the precursor web 30′ is fed into the deforming nip106 between first forming roll 102 and second forming roll 104. Afterleaving the deforming nip 106, the deformed web 30 is wrapped partiallyaround the first forming roll, male roll 102. While the web 30 is stillin contact with the male roll 102, it passes through a second nip 156between male roll 102 and the additional bonding roll 150. Theadditional bonding roll 150 can compress the fibers at the distal ends54 of the protrusions 32 sufficient to partially melt and bond thefibers at this location together. Heat and/or ultrasonics may also beused to help facilitate bonding. As shown in FIG. 29, this produces aprotrusion 32 in which the deformed nonwoven material 30 is bondedtogether at the tops (or distal ends 54) of the protrusions 32. Thedeformed tip bonded web 30 then passes between male roll 102 and secondfemale roll 104A. After that, the deformed tip bonded web 30 is wrappedpartially around the second female roll 104A. While the web 30 is stillin contact with the second female roll 104A, it passes through a secondnip 166 between the second female roll 104A and the additional bondingroll 160. The additional bonding roll 160 can compress the fibers in theundeformed first region 40 outside of the bases 50 of the protrusions 32sufficient to partially melt and bond the fibers at this locationtogether. Heat and/or ultrasonics may also be used to help facilitatebonding. This will provide the tip bonded web with base bonds 168 whichmay be continuous as shown in FIG. 33A, or discrete as shown in FIG. 34.

2. Bonding the Nonwoven Materials to an Additional Layer.

In other embodiments, a deformed nonwoven material can be bonded toanother material to form a composite web or sheet. The term “sheet” willbe used herein to refer to a portion (e.g., a discrete length) of a webthat has been cut into an individual piece from the web, typically as afinal step in a manufacturing process. Therefore, if a property isdescribed herein as being present in the composite web, it will also bepresent in the composite sheet. The components of the composite sheetmay be described as being “partially bonded” together. By this it ismeant that the components are bonded together at certain locations ontheir surfaces, and are not bonded together over their entire surfaces.The components of the composite sheet in any of the embodimentsdescribed herein can be bonded together using any suitable type ofbonding process including, but not limited to ultrasonics, adhesives,and heat and/or pressure, or combinations of the same.

a) Tip Bonding.

In some embodiments, a deformed nonwoven material can be bonded toanother material to form a composite web or sheet by bonding the layerstogether at the tops or distal ends 54 of the protrusions 32 of thedeformed nonwoven material.

FIG. 30 shows one embodiment of an apparatus 100 similar to that shownin FIG. 28. The apparatus shown in FIG. 30 deforms the nonwoven materialand also includes an additional bonding roll 150. In this embodiment,the bonding roll 150 is used for bonding the deformed nonwoven material30 to an additional layer 158 at the distal ends 54 of the protrusions32 in the deformed nonwoven material 30. As shown in FIG. 30, theadditional bonding roll 150 is located downstream of the first nip,deforming nip 106. The bonding roll 150 can have any suitable surfaceconfiguration. In some embodiments, the surface of the bonding roll 150may be substantially smooth. In other cases, the bonding roll 150 mayhave a plurality of bonding elements 154 protruding from the surface ofthe bonding roll 150. The second nip 156 is formed between the male roll102 and the bonding roll 150.

The nonwoven web with deformations therein, which comprises a first web30, and a second nonwoven web 170 are fed into the second nip 156.Vacuum, hold down belts, or some other mechanism could be used to keepthe deformed web 30 seated on the first forming roll 102 as it istransferred to the second nip 156. The nonwoven web 30 with deformationstherein can be a single layer nonwoven web or a dual or multiple layernonwoven web. The second nonwoven web 170 can comprise any of the typesof nonwoven webs specified as being suitable for use as precursor websfor the nonwoven material. The second nonwoven web 170, however, neednot be deformed as in the case of the first web 30, and thus may besubstantially planar. In some embodiments, at least one of the first web30 and second web 170 comprises a spunbond nonwoven which has discretebond sites 46 therein. The first web 30 can have any of thecharacteristics of the deformed nonwoven materials described herein(e.g., one or more layers, bulbous protrusions, bond sites, areas withdifferent fiber concentration, etc.). The bonding roll 150 can have anyother properties (heated or unheated) and manner of bonding (compressionand/or melting) in the tip bonding process described above. In addition,adhesive may be applied to the second nonwoven web 170 prior to thesecond nip 156 in order to facilitate bonding.

The second nip 156 bonds at least a portion of the distal ends 54 of theprotrusions in the first web 30 to the second web 170 to form atip-bonded composite web 172 in which the first and second webs arebonded together at inter-web bond sites 174. The first web 30 has afirst region 40 that can be considered to have an X-directionorientation (which may be in the machine direction), a Y-directionorientation (which may be in the cross-machine direction), and theprotrusions 32 extend outward therefrom in the Z-direction. Theinter-web bond sites 174 are spaced apart in the X-direction and theY-direction so that the composite web 172 has unbonded regions betweenthe inter-web bond sites 174 in all directions. This differs fromcorrugated materials which typically contact and are bonded to a secondlayer along the length of the corrugations rather than at discrete bondsites.

The inter-web bond sites 174 comprise bonded portions of the protrusions32. In some embodiments, the bonded portions 174 of the protrusions 32may comprise fibers that are more densely packed than the fibers in thefirst region 40 of the first web or sheet 30. In some cases, at leastportions of the fibers in the bonded portions 174 of the protrusions 32may be melted. In those cases in which the surface of the bonding roll150 is substantially smooth, the inter-web bond sites 174 will be formedon substantially the entire distal ends 54 of the protrusions 32 in thefirst web 30. In those cases in which the bonding roll 150 has aplurality of discrete, spaced-apart bonding elements 154 protruding fromthe surface of the bonding roll 150, the bonding elements 154 will onlybond a portion of the distal ends 54 of the protrusions 32 in the firstweb 30. In some cases, the inter-web bond sites 174 can be formed inless than or equal to 25% of the area on the distal ends 54 of theprotrusions 32.

Forming a composite sheet by bonding the deformed nonwoven material 30to another layer or material is believed to improve the resiliency ofthe deformed web material 30 to compressive forces.

b) Base Bonding.

In still other embodiments, the deformed nonwoven material 30 can bebonded to another material to form a composite sheet by bonding thelayers together at the base of the protrusions of the deformed nonwovenmaterial. The layers of the composite sheet can be bonded together usingany suitable type of bonding process including, but not limited toultrasonics, adhesives, and heat and/or pressure, or combinations of thesame.

FIG. 35 shows one embodiment of an apparatus 100 for deforming thenonwoven material which includes an additional bonding roll 160 forbonding the deformed nonwoven material 30 to an additional layer outsidethe base 50 of the protrusions 32 of the deformed nonwoven material 30.As shown in FIG. 35, the additional bonding roll 160 is locateddownstream of the first nip 106. The second nip 166 is formed betweenthe female roll 104 and the bonding roll 160.

The nonwoven web 30 with deformations therein, which comprises a firstsheet and a second nonwoven web 180 are fed into the second nip 166.Vacuum, hold down belts, or some other mechanism could be used to keepthe deformed web 30 seated on the female roll 104 as it is transferredto the second nip 166. The nonwoven web 30 with deformations therein canbe a single layer nonwoven web or a dual or multiple layer nonwoven web.The second nonwoven web 180 can comprise any of the types of nonwovenwebs specified as being suitable for use as precursor webs for thenonwoven material and can have any of the properties of the secondnonwoven web 170 in the tip bonding process (of the deformed nonwoven toan additional layer) described above.

The second nip 166 bonds at least a portion of the deformed nonwoven web30 outside the base 50 of the protrusions 32 in the first web 30 to thesecond web 180 to form a base-bonded composite web or sheet 182 in whichthe first and second webs are bonded together at inter-web bond sites184. As in the case of the tip bonding process, the inter-web bond sites184 are spaced apart in the X-direction and the Y-direction.

The inter-web bond sites 184 comprise bonded portions at the base 50 ofthe protrusions 32 outside of the deformations and in the first region40 of the first web 30 to form a base-bonded composite web 182. In someembodiments, the base bonded portions 184 may comprise fibers that aremore densely packed than the fibers in the first region 40 of the firstweb 30. In some cases, at least portions of the fibers in the basebonded portions 184 of the first web 30 may be melted.

There are a number of variations of the roll configurations in thebonding step. The surface of the bonding roll 160 may be substantiallysmooth. Alternatively, as shown in FIGS. 35 and 35C, it can have aplurality of discrete, spaced-apart bonding elements 162 protruding fromits surface. The portions of the surface 124 of the female roll 104 thatare located outside of the recesses 114 in the female roll 104 may alsobe substantially smooth, or they may have a plurality of discrete,spaced-apart bonding elements 164 protruding from the surface 124. Thebonding elements 164 on the surface 124 of the female roll 104 may bediscrete, spaced-apart bonding elements 164 as shown in FIG. 35A, orthey may be continuous bonding elements 164 as shown in FIG. 35B.

In those cases in which the surface of the bonding roll 160 issubstantially smooth, the inter-web bond sites 184 may be at leastsubstantially continuous and may substantially or completely surroundthe deformations in the first web 30 similar to the base bond sites 168shown in FIG. 33A.

In those cases in which the bonding roll 160 or the female roll 104 havea plurality of discrete, spaced-apart bonding elements 162 and 164,respectively, protruding from their surfaces, the bonding elements willonly bond discrete, spaced-apart regions of the first web 30 (that lieoutside of the deformations) to the second web 180. In such cases, theinter-web bonds 184 may be located in at least two discrete portions ofthe first region 40 which are adjacent to and lie outside of at leastsome of the deformations. Thus, in such cases there may be at least twointer-web base bond sites 184 for a given deformation similar to thebase bond sites 168 shown in FIG. 34.

c) Tip and Base Bonding.

In other embodiments, the deformed nonwoven material 30 can be tipbonded or base bonded as described above, and then also bonded toanother material to form a composite web or sheet.

FIG. 41 shows one embodiment of an apparatus 100 for carrying out a tipbonding process in which the tip bonded deformed nonwoven web 30 is thenbase bonded to another material to form a composite web or sheet. Theapparatus 100 shown in FIG. 41 is similar to the apparatus shown in FIG.40. FIG. 41 differs from the apparatus shown in FIG. 40 in that anadditional layer 180 is fed into the apparatus and is bonded to thedeformed nonwoven material 30 outside the base 50 of the protrusions 32of the deformed nonwoven material 30. This aspect of the apparatus shownin FIG. 41 (feeding an additional layer for base bonding) is similar tothat shown in FIG. 35. Therefore, the description of the apparatus shownin FIG. 41 will incorporate the above descriptions of the apparatusesshown in FIGS. 35 and 40, and will not be repeated in its entiretyherein.

As shown in FIG. 41, the precursor web 30′ is fed into the deforming nip106 between first forming roll 102 and second forming roll 104. Afterleaving the deforming nip 106, the deformed web 30 is wrapped partiallyaround the first forming roll, male roll 102. While the web 30 is stillin contact with the male roll 102, it passes through a second nip 156between male roll 102 and the additional bonding roll 150. Theadditional bonding roll 150 can compress the fibers at the distal ends54 of the protrusions 32 sufficient to partially melt and bond thefibers at this location together. As shown in FIG. 29, this produces aprotrusion 32 in which the deformed nonwoven material 30 is bondedtogether at the tops (or distal ends 54) of the protrusions 32. Thedeformed tip bonded web 30 then passes between male roll 102 and secondfemale roll 104A. After that, the deformed tip bonded web 30 is wrappedpartially around the second female roll 104A. While the web 30 is stillin contact with the second female roll 104A, it passes through a secondnip 166 between the second female roll 104A and the additional bondingroll 160. The second nip 166 bonds at least a portion of the deformednonwoven web 30 outside the base 50 of the protrusions 32 in the firstweb 30 the second web 180 to form a base-bonded composite web or sheet182 in which the first and second webs are bonded together at inter-webbond sites 184. The inter-web base bonds 184 may be continuous similarto the base bonds 168 shown in FIG. 33A, or discrete similar to the basebonds 168 shown in FIG. 34.

FIG. 42 shows one embodiment of an apparatus 100 for carrying out a basebonding process in which the base bonded deformed nonwoven web 30 isthen tip bonded to another material to form a composite web or sheet.

The rolls 102, 104, and 160 shown in FIG. 42 comprise the base bondingportion of the apparatus, which is similar to the apparatus shown inFIG. 32. FIG. 42 differs in that the precursor web 30′ is shown as beingfed into the deforming nip 106 from the right side, instead of the leftside, and the deformed web 30 wraps partially around female roll 102instead of bonding roll 160 after it leaves the deforming nip 106.Therefore, the description of this portion of the apparatus willincorporate the above description of the apparatus shown in FIG. 32, andwill not be repeated in its entirety herein.

The apparatus shown in FIG. 42 further comprises a second male roll 102Aand a tip bonding roll 150. The female roll 104, the second male roll102A, and the tip bonding roll 150 comprise the tip bonding portion ofthe apparatus, which is similar to the apparatus shown in FIG. 30. FIG.42 differs in that the deformed bonded web 30 is shown as wrappingaround the second male roll 102A as it leaves the apparatus in FIG. 42,instead of wrapping around the tip bonding roll 150. Therefore, thedescription of this portion of the apparatus will incorporate the abovedescription of the apparatus shown in FIG. 30, and will not be repeatedin its entirety herein.

As shown in FIG. 42, the precursor web 30′ is fed into the deforming nip106 between first forming roll 102 and second forming roll 104. Afterleaving the deforming nip 106, the deformed web 30 is wrapped partiallyaround the second forming roll, female roll 104. While the web 30 isstill in contact with the female roll 104, it passes through a secondnip 166 between female roll 104 and the additional bonding roll 160 forbase bonding the deformed nonwoven material 30. The additional bondingroll 160 can compress the fibers in the undeformed first region 40outside of the bases 50 of the protrusions 32 sufficient to partiallymelt and bond the fibers at this location together. This will providethe base bonded web with base bonds 168 which may be continuous similarto those shown in FIG. 33A, or discrete similar to those shown in FIG.34. The deformed base bonded web 30 then passes between female roll 104and second male roll 102A. After that, the deformed base bonded web 30is wrapped partially around the second male roll 102A. While the web 30is still in contact with the second male roll 102A, it passes through asecond nip 156 between the second male roll 102A and the additionalbonding roll 150.

At the second nip 156, an additional layer 170 is fed into the apparatusand is bonded to the deformed nonwoven material 30 at the tops (ordistal ends 54) of the protrusions 32. This will form a composite web orsheet 172 similar to that shown in FIG. 31 comprising a base bondeddeformed web 30 that is tip bonded to a second web 170.

V. Test Methods

A. Accelerated Compression Method.

-   -   1. Cut 10 samples of the specimen to be tested and 11 pieces of        a paper towel into a 3 inch×3 inch (7.6 cm×7.6 cm) square.    -   2. Measure the caliper of each of the 10 specimens at 2.1 kPa        and a dwell time of 2 seconds using a Thwing-Albert ProGage        Thickness Tester or equivalent with a 50-60 millimeter diameter        circular foot. Alternatively, a pressure of 0.5 kPa can be used.        Record the pre-compression caliper to the nearest 0.01 mm.    -   3. Alternate the layers of the specimens to be tested with the        pieces of paper towel, starting and ending with the paper        towels. The choice of paper towel does not matter and is present        to prevent “nesting” of the protrusions in the deformed samples.        The samples should be oriented so the edges of each of the        specimens and each of the paper towels are relatively aligned,        and the protrusions in the specimens are all oriented the same        direction.    -   4. Place the stack of samples into a 40±2° C. oven at 25±3%        relative humidity and place a weight on top of the stack. The        weight must be larger than the foot of the thickness tester. To        simulate high pressures or low in-bag stack heights, apply 35        kPa (e.g. 17.5 kg weight over a 70×70 mm area). To simulate low        pressures or high in-bag stack heights, apply 7.0 kPa (e.g. 3.4        kg weight over a 70×70 mm area), 4.0 kPa (e.g., 1.9 kg weight        over a 70×70 mm area) of 1.0 kPa (e.g., 0.49 kg weight over a        70×70 mm area).    -   5. Leave the samples in the oven for 15 hours. After the time        period has elapsed, remove the weight from the samples and        remove the samples from the oven.    -   6. Within 30 minutes of removing the samples from the oven,        measure the post-compression caliper as directed in step 2        above, making sure to maintain the same order in which the        pre-compression caliper was recorded. Record the        post-compression caliper of each of the 10 specimens to the        nearest 0.01 mm.    -   7. Let the samples rest at 23±2° C. at 25±3% relative humidity        for 24 hours without any weight on them.    -   8. After 24 hours, measure the post-recovery caliper of each of        the 10 specimens as directed in step 2 above, making sure to        maintain the same order in which the pre-compression and        post-compression calipers were recorded. Record the        post-recovery caliper of each of the 10 specimens to the nearest        0.01 mm. Calculate the amount of caliper recovery by subtracting        the post-compression caliper from the post-recovery caliper and        record to the nearest 0.01 mm.    -   9. If desired, an average of the 10 specimens can be calculated        for the pre-compression, post-compression and post-recovery        calipers.

B. Tensile Method

The MD and CD tensile properties are measured using World StrategicPartners (WSP) (harmonization of the two nonwovens organizations of INDA(North American based) and EDANA (Europe based)) Tensile Method 110.4(05) Option B, with a 50 mm sample width, 60 mm gauge length, and 60mm/min rate of extension. Note that the gauge length, rate of extensionand resultant strain rate are from different from that specified withinthe method.

C. Surface Texture Characterization Method

The microscale surface texture of male elements is analyzed using a 3DLaser Scanning Confocal Microscope (suitable 3D Laser Scanning ConfocalMicroscope is the Keyence VK-X210, commercially available from KeyenceCorporation of America, Itasca, Ill., USA). The microscope is interfacedwith a computer running a measuring, control, and surface textureanalysis software (suitable software is Keyence VK Viewer version2.2.0.0 and Keyence VK Analyzer version 3.3.0.0, commercially availablefrom Keyence Corporation of America, Itasca, Ill., USA).

The 3D surface Laser Scanning Confocal Microscope measures the surfaceheights of a specimen, and produces a map of surface height(z-directional or z-axis) versus displacement in the x-y plane. Thesurface map is then analyzed according to ISO 25178-2:2012, from whichthe areal surface texture parameters Sq, Sxp, Str and Vmp arecalculated. These parameters describe key characteristics of the maleelement surface.

Using a 20× objective lens, a 1.0× zoom level and a 0.50 μm pitch(Z-step size), the microscope is programmed to collect a surface heightimage with a field of view of at least 500 μm×700 μm with an x-y pixelresolution of approximately 0.7 microns (μm)/pixel. If a larger field ofview is required, multiple scans, maintaining the x-y resolution, overthe surface can be collected and stitched together into a single imagefor analysis. The height resolution is set at 0.1 nm/digit, over asufficient height range to capture all peaks and valleys within thefield of view.

Calibrate the instrument according to the manufacturer's specifications.

Place the male element specimen on the stage beneath the objective lens.Collect a surface height image (z-direction) of the specimen byfollowing the instrument manufacturer's recommended measurementprocedures, which may include using the following settings to minimizenoise and maximize the quality of the surface data: Real Peak Detection,single/double scan, surface profile mode, standard area, high-accuracyquality; laser intensity (Brightness and ND filter) set using auto gain.Save the surface height image.

Open the surface height image in the surface texture analysis software.ISO 25178-2:2012 describes a recommended filtration process, accordinglythe following filtering procedure is performed on each image: 1) aGaussian low pass S-filter with a nesting index (cut-off) of 2.5 μm; 2)an F-operation of plane tilt (auto) correction; and 3) a Gaussian highpass L-filter with a nesting index (cut-off) of 0.25 mm. Both Gaussianfilters are run utilizing end effect correction. This filteringprocedure produces the SL surface from which the areal surface textureparameters will be calculated.

Select the entire field of view for measurement, and calculate the arealsurface roughness parameters on the SL Surface.

The surface texture parameters Sq, Sxp, Str and Vmp are described in ISO25178-2:2012. Sq is the root mean square of the profile heights of theroughness surface. The units of Sq are μm. The parameters Sxp and Vmpare derived from the Areal Material Ratio (Abbott-Firestone) curvedescribed in the ISO 13565-2:1996 standard extrapolated to surfaces, itis the cumulative curve of the surface height distribution histogramversus the range of surface heights. A material ratio is the ratio,given as a %, of the intersecting area of a plane passing through thesurface at a given height to the cross sectional area of the evaluationregion. The Peak Extreme Height, Sxp, is a measure of the difference inheights on the surface from the areal material ratio value of 2.5%(highest peaks, excluding outliers) to the areal material ratio value of50% (the mean plane). The units of Sxp are μm. The Peak Material Volume,Vmp, is the actual volume of material comprising the surface from theheight corresponding to a material ratio value of 10% to the highestpeak (material ratio of 0%). The units of Vmp are mL/m². The TextureAspect Ratio, Str, is a measure of the spatial isotropy ordirectionality of the surface texture. Str is a spatial parameter whichinvolves the use of the mathematical technique of the autocorrelationfunction. The Str parameter has a value range between 0 and 1, and isunitless. An isotropic surface will have Str close to 1, while astrongly anisotropic surface will have Str close to 0. Str is calculatedusing a thresholding value of s=0.2. If a Str value is unable to becalculated, rotate the specimen by 30 degrees, rescan and reanalyze thesurface.

Scan and analyze the surface textures of three replicate male elements.Average together the three Sq values and report to the nearest 0.01 μm.Average together the three S×p values and report to the nearest 0.01 μm.Average together the three Vmp values and report to the nearest 0.01mL/m². Average together the three Str values and report to the nearest0.01 units.

D. Light Transmission.

The feature and land area light transmission method measures the averageamount of light transmitted through specific regions of a specimen. Acalibrated light transmission image is obtained using a flatbed scanner.A binary mask is generated using a corresponding surface topographyimage that is thresheld at a given height to separate discrete featureregions from the surrounding land area. The binary mask is thenregistered to the light transmission image, and used to isolate thediscrete features from the land area in the light transmission image.This enables the average light transmission value for each region to becalculated.

Sample Preparation—Topsheet/Underlying Layer Laminate

Tape the absorbent article to a rigid flat surface in a planarconfiguration with the body-facing surface up. Any leg elastics may becut to facilitate laying the article flat. The entiretopsheet/underlying layer (e.g. acquisition layer) laminate specimen isthen carefully removed from the article. A scalpel and/or cryogenicspray (such as Cyto-Freeze, Control Company, Houston Tex. USA) can beused to remove the specimen from additional underlying layers, ifnecessary, to avoid any longitudinal and lateral extension of thespecimen. The topsheet/underlying layer laminate specimen should behandled only with forceps around its peripheral edge. If the topsheet isnot joined to an underlying layer, carefully remove only the topsheetlayer as the specimen.

Identify a 40 mm×40 mm square region centered at, with the sidesparallel to, the longitudinal and lateral centerlines of the specimen.Create registration marks on the specimen surface by using a blackmarker to make a small dot in the four corners of the identified 40mm×40 mm square analysis region. Similarly, identify and mark a secondand a third 40 mm×40 mm square analysis region. The second centeredalong the longitudinal centerline 50 mm inboard from the leading edge ofthe topsheet/underlying layer laminate, and the third centered along thelongitudinal centerline 50 mm inboard from the trailing edge of thetopsheet/underlying layer laminate. Depending on the length of thespecimen the identified regions may overlap each other, if so, followthe procedure as described and analyze the entirety of each of the threeregions. If the topsheet is not joined to an underlying layer, identifyand mark the three 40 mm×40 mm analysis regions in like fashion, exceptuse the leading and trailing edges of the topsheet to identify thelocation of the second and third analysis regions.

Five replicate topsheet/underlying layer laminate specimens are obtainedfrom five substantially similar absorbent articles are similarlyprepared for analysis. Precondition the specimens at about 23° C.±2 C.°and about 50%±2% relative humidity for 2 hours prior to testing.

Light Transmission Image

The color difference (delta E*) measurement is based on the CIE L* a* b*color system (CIELAB). A flatbed scanner capable of scanning a minimumof 24 bit color at 800 dpi and has manual control of color management (asuitable scanner is an Epson Perfection V750 Pro from Epson AmericaInc., Long Beach Calif. USA) is used to acquire images. The scanner isinterfaced with a computer running color management software (suitablecolor management software is MonacoEZColor available from X-Rite GrandRapids, Mich. USA). The scanner is calibrated against a colortransparency target and corresponding reference file compliant with ANSImethod IT8.7/1-1993 using the color management software to construct acalibrated color profile. The resulting calibrated scanner profile isused to color correct an image from a test specimen within an imageanalysis program that supports sampling in CIE L* a* b* (a suitableprogram is Photoshop S4 available from Adobe Systems Inc., San Jose,Calif. USA). All testing is performed in a conditioned room maintainedat about 23±2° C. and about 50±2% relative humidity.

Turn on the scanner for 30 minutes prior to calibration. Deselect anyautomatic color correction or color management options that may beincluded in the scanner software. If the automatic color managementcannot be disabled, the scanner is not appropriate for this application.Place the IT8 target face down onto the scanner glass, close the scannerlid, acquire an image at 200 dpi and 24 bit color and remove the IT8target. Open the image file on the computer with the color managementsoftware. Follow the recommended steps within the color managementsoftware to create and export a calibrated color profile. These stepsmay include, ensuring that the scanned image is oriented and croppedcorrectly. The calibrated color profile must be compatible with theimage analysis program. The color management software uses the acquiredimage to compare with the included reference file to create and exportthe calibrated color profile. After the profile is created the scanresolution (dpi) for test specimens can be changed, but all othersettings must be kept constant while imaging specimens.

Open the scanner lid and place the specimen flat against the scannerglass with the skin facing surface facing the glass. Acquire and importa scan of the 40 mm×40 mm marked region of the specimen into the imageanalysis software at 24 bit color and at 800 dpi in transparency mode.Transparency mode illuminates the specimen from one side with the sensorcapturing the image from the opposite side. Ensuring that each of thefour registration marks are located in the corners of the scanned image.Assign the calibrated color profile to the image and change the colorspace mode to L*a*b* Color corresponding to the CIE L* a* b* standard.This produces a color corrected image for analysis. Save this colorcorrected image in an uncompressed format, such as a TIFF file.

Feature Area and Land Area Mask

The boundaries of the discrete feature areas and land area areidentified by thresholding a 3D surface topography image at a specifiedheight to generate a binary image, separating discrete feature areasfrom the surrounding land area. This binary image will then be used as amask on the corresponding light transmission image to measure theaverage Light Transmission Values of the discrete feature areasseparately from the average Light Transmission Values of the surroundingland area.

The 3D surface topography image is obtained using an optical 3D surfacetopography measurement system (a suitable optical 3D surface topographymeasurement system is the GFM MikroCAD Premium instrument commerciallyavailable from GFMesstechnik GmbH, Teltow/Berlin, Germany). The systemincludes the following main components: a) a Digital Light Processing(DLP) projector with direct digital controlled micro-mirrors; b) a CCDcamera with at least a 1600×1200 pixel resolution; c) projection opticsadapted to a measuring area of at least 60 mm×45 mm; d) recording opticsadapted to a measuring area of 60 mm×45 mm; e) a table tripod based on asmall hard stone plate; f) a blue LED light source; g) a measuring,control, and evaluation computer running surface topography analysissoftware (suitable software is ODSCAD software version 6.2 availablefrom GFMesstechnik GmbH, Teltow/Berlin, Germany); and h) calibrationplates for lateral (x-y) and vertical (z) calibration available from thevendor.

The optical 3D surface topography measurement system measures thesurface height of a specimen using the digital micro-mirror patternfringe projection technique. The result of the analysis is a map ofsurface height (z-directional or z-axis) versus displacement in the x-yplane. The system has a field of view of 60×45 mm with an x-y pixelresolution of approximately 40 microns. The height resolution is set at0.5 micron/count, with a height range of +/−15 mm. All testing isperformed in a conditioned room maintained at about 23±2° C. and about50±2% relative humidity.

Calibrate the instrument according to manufacturer's specificationsusing the calibration plates for lateral (x-y axis) and vertical (zaxis) available from the vendor.

Place specimen on the table beneath the camera. Center the marked 40mm×40 mm analysis region of the specimen within the camera field ofview, so that only the specimen surface is visible in the image. Place asteel frame (100 mm square, 1.5 mm thick with an opening 70 mm square)on the sample to ensure the specimen lays flat with minimal wrinkles,and still allows for an unobstructed access to the surface area beingscanned.

Collect a height image (Z-direction) of the specimen by following theinstrument manufacturer's recommended measurement procedures, which mayinclude, focusing the measurement system and performing a brightnessadjustment. No pre-filtering options should be utilized. Save thecollected height image file.

Load the height image into the surface analysis portion of the software.The following filtering procedure is then performed on each image: 1)remove invalid points; 2) a 3×3 pixel median filter to remove noise; 4)an automatic planar alignment to remove form; and 3) a Gaussian highpass filter with a cut-off wavelength of 10 mm to filter out large scalewaviness in the sample. Crop the image to the 40 mm×40 mm square areaidentified by the registration marks, so that each of the fourregistration marks are located in the four corners of the cropped image.

Determination of the thresholding height level utilizes the ArealMaterial Ratio (Abbott-Firestone) curve, described in the ISO13565-2:1996 standard extrapolated to surfaces. It is the cumulativecurve of the surface height distribution histogram versus the range ofsurface heights.

A material ratio is the ratio, given as a %, of the intersecting area ofa plane passing through the surface at a given height (cutting depth) tothe cross sectional area of the evaluation region. If the specimencontains discrete features which are depressions oriented downwardrelative to the body facing surface or contains apertures, threshold thesurface topography image at a cutting depth where the material ratio is75%. A material ratio of 75% separates the deep valleys from the landarea region. If the specimen contains discrete features which areprotrusions or tufts oriented upward, threshold the surface topographyimage at a cutting depth where the material ratio is 25%. A materialratio of 25% separates the protruding peaks from the land area region.By thresholding at the levels described above, a binary mask image isproduced with the discrete feature areas assigned one value, and thesurrounding land area assigned a different value. For example, thediscrete feature areas could appear black, and the surrounding land areacould appear white. Save this binary mask image in an uncompressedformat, such as a TIFF file.

Analysis of Light Transmission Image

Open both the color corrected light transmission image and thecorresponding binary mask image in the image analysis software. Toanalyze the specimen light transmission image, first separate the L*, a*and b* channels, and select only the L* channel for analysis. The L*channel represents the “Lightness” of the image and has values thatrange from 0-100. Register the light transmission image and the binarymask image to each other so that the corresponding registration marksare aligned. Use the mask to remove the land area from the lighttransmission image, and calculate the average L* value (LightTransmission Value) for the remaining discrete features. Record thisvalue as the Feature Light Transmission Value to the nearest 0.1 units.Then use the binary mask to remove the discrete features from the lighttransmission image, and calculate an average L* value (LightTransmission Value) for the remaining surrounding land area. Record thisvalue as the Land Area Light Transmission Value to the nearest 0.1units. Repeat this procedure for the other two regions on the specimen.Calculate the difference between the Feature Light Transmission Valueand the Land Area Light Transmission Value for each of the threeanalyzed regions on a single specimen. Compare the three differences andkeep the Feature Light Transmission Value and Land Area LightTransmission Value from the 40 mm×40 mm analysis region with the highestdifference and discard the values from the other two regions. In likefashion repeat this procedure on all of the replicate specimens.Calculate and report the average of the five individual Feature LightTransmission Values and Land Area Light Transmission Values to thenearest 0.1 units.

VI. Examples Comparative Example 1

In Comparative Example 1, the material is a composite of two materialsglued together using H. B. Fuller of St. Paul, Minn., U.S.A. D3166ZP hotmelt adhesive applied in a spiral pattern at a 1 gsm add on level. Thecomposite material is processed through a nip formed by one of TheProcter & Gamble Company's SELF rolls and a ring roll as described inU.S. Pat. No. 7,410,683 B2, Curro, et al., at 25 feet/minute (fpm) (7.6meters per minute) and 0.135″ (3.43 mm) DOE. The material layer incontact with the SELF roll is a 20 gsm spunbond nonwoven produced byFitesa of Simpsonville, S.C., U.S.A. Such a material is described inFitesa's U.S. patent application Ser. No. 14/206,699 entitled“Extensible Nonwoven Fabric” and is comprised of 2.5 denier fiberscomprising a blend of PP and PE The material layer in contact with thering roll is a 43 gsm spunbond nonwoven produced by Reicofil ofTroisdorf, Germany, comprised of 7 denier co-PET/PET tipped-trilobalbicomponent fibers.

Example 1 Single Layer

In Example 1, the material is a 50 grams/m² (gsm) PE/PP sheath/corebicomponent spunbond nonwoven from Fitesa. It is processed at 25 fpm(7.6 meters per minute) speed at 0.155 inch (3.94 mm) depth ofengagement (DOE) through male/female tooling (forming members). Theteeth on the male tool have a rounded diamond shape like that shown inFIG. 21, with vertical sidewalls and a radiused or rounded edge at thetransition between the top and the sidewalls of the male element. Theteeth are 0.186 inch (4.72 mm) long and 0.125 inch (3.18 mm) wide with aCD spacing of 0.150 inch (3.81 mm) and an MD spacing of 0.346 inch (8.79mm). The recesses in the mating female roll also have a rounded diamondshape, similar to that of the male roll, with a clearance between therolls of 0.032-0.063 inch (0.813-1.6 mm), varying slightly around theperimeter of the recess.

Example 2 Two Layers

In Example 2, the material is a composite of two materials gluedtogether using the same hot melt adhesive applied in a spiral pattern asdescribed in Comparative Example 1. It is processed through themale/female tooling described in Example 1, at 800 feet per minute (fpm)(24.4 meters per minute) and 0.155 inch (3.94 mm) DOE. The materiallayer in contact with the male roll is the 20 gsm spunbond nonwovenproduced by Fitesa comprised of 2.5 denier fibers with a blend of PP andPE described in Comparative Example 1. The material layer in contactwith the female roll is a 60 gsm through-air bonded carded nonwovenproduced by Beijing Dayuan Non-Woven Fabric Co, LTD of Beijing, China,comprised of 5 denier PE/PET sheath/core bicomponent fibers.

Example 3 Two Layers

In Example 3, the material is a composite of two materials gluedtogether using the same hot melt adhesive applied in a spiral pattern asdescribed in Comparative Example 1. It is processed through themale/female tooling described in Example 1, at 800 fpm and 0.155 inch(3.94 mm) DOE. The material layer in contact with the male roll is a 20gsm spunbond nonwoven produced by Fitesa comprised of 2.5 denier fiberswith a blend of PP and PE described in Example 2. The material layer incontact with the female roll is an 86 gsm spunbond nonwoven produced byReicofil comprised of 7 denier co-PET/PET tipped-trilobal bicomponentfibers.

The samples are compressed for 15 hours according to the AcceleratedCompression Method, with a 3.4 kg weight (7 kPa). The pre-compressioncaliper and the post-compression caliper of the samples are measuredfollowing the Accelerated Compression Method under 2.1 kPa pressure. Thedimensions of the protrusions and openings are measured using amicroscope at 20× magnification. The exterior dimensions of the cap aremeasured from a perspective view with the protrusions facing up, likethat shown in FIG. 5. The protrusion depth and the interior cap width ismeasured from the cross-section of the material like that shown in FIG.11.

TABLE 2 Material Examples Ratio of Cap First Second Measured Base Capwidth- Layer Layer Before or Opening Base Width- Cap Cap Interior(Contacts (Contacts After Caliper at Protrusion Width Opening InteriorWidth- Length- to Base Exam- Male Female Compression 2.1 kPa Depth (W₀)Length (W₁) Exterior Exterior Opening ple Tool) Tool) (7 kPa) (mm) (mm)(mm) (mm) (mm) (mm) (mm) Width Comp. 20 gsm 43 gsm Before 1.2 1.1 0.54.7 <0.1* 1.5 4.6 — Ex. 1 Spunbond co- Compression (Tuft) (Tuft) (Tuft)(Tuft) PE/PP PET/PET After 0.7 0.3 0* 4.7 0* 0.7 4.0 — Blend SpunbondCompression (opening (opening was was closed) closed) Ex. 1 50 gsm NoneBefore 0.48 1.3 1.5 3.3 1.7 2.4 4.2 1.1 PE/PP Compression Bico After0.39 0.4 1.7 3.0 2.1 2.9 4.3 1.2 Spunbond Compression Ex. 2 20 gsm 60gsm Before 1.6 1.9 1.9 3.5 2.4 3.2 4.5 1.3 Spunbond PET CompressionPE/PP Carded After 0.88 0.5 1.6 3.3 1.8 2.7 4.4 1.1 Blend Through-Compression air Bonded Ex. 3 20 gsm 86 gsm Before 2.0 1.9 1.8 3.8 2.23.8 4.8 1.2 Spunbond co- Compression PE/PP PET/PET After 1.3 0.7 1.5 3.62.5 3.7 5.2 1.7 Blend Spunbond Compression *Difficult to measure becausemeasurement was so small

Example 4 Light Transmission Differences

FIGS. 37-40 show images of several nonwoven topsheets that have beenformed by different processes. Each has discrete features that areformed into the materials.

FIG. 37 shows a nonwoven material 30 as described herein shown with thebase openings 44 facing upward (which appear as depressions). Thenonwoven material 30 comprises two layers that are joined together toform a topsheet and underlying acquisition layer. The layers comprise a25 gsm polyethylene/polypropylene bicomponent fiber topsheet layer and a43 gsm spunbond PET acquisition layer, glued together with 1 gsm spiralglue pattern that have been run through the deformation processdescribed herein. The nonwoven material 30 comprises a generally planarfirst region 40 and a plurality of discrete integral second regions 42that comprise spaced apart deformations (the depressions) in thenonwoven material. The first region 40 may form a continuousinter-connected network region wherein portions of the network surroundeach of the (depressions) deformations.

The first region 40 has a first light transmission value and the secondregions 42 have a second transmission value. The light transmissionvalues are summarized in Table 3 below. The second light transmissionvalue in the deformations is at least about 5 units greater,alternatively at least about 9 units, alternatively about 10 unitsgreater, than the first light transmission value. In this example, thefibers are not densified or melted together, which could also result ina higher light transmission value. The method of making the nonwoven webdescribed herein creates that difference by rearranging the fibers inthe web, resulting in a lower fiber concentration, and therefore ahigher light transmission value, in the bottom of the depressions. Thedeformations/second regions 42 have a light transmission of less than orequal to about 90 units, indicating the absence of a through-hole in thebottom of the deformations. (For comparison, FIG. 38 is a photograph ofan apertured nonwoven material. An aperture that is substantially clearof fibers has a light transmission value of between 95-100 units).

The nonwoven material 30 described herein is unique in that (like thetopsheet shown in FIG. 38) it creates the “look” of an aperture that hasdepth, making it appear absorbent and dry, but without some of thesoftness negatives (technical and perceptual) associated with someapertures. Due to the increase in translucency in the deformation,placing a colored layer behind the nonwoven material 30 could result incolor showing through primarily in the depression, high-lighting thedepression and, in some cases, making it appear to have even more depth.

FIG. 39 is a photograph of a currently marketed Kimberly-Clark HUGGIES®diaper topsheet 190 which has discrete portions or tufts 192 orientedupward. In this example, the light transmission value in the discreteportions 192 is in the opposite relationship to that of the nonwovenmaterial in FIG. 37. The light transmission value in the discreteportions 192 is at least about 5 units lower, and more typically is atleast about 7 units lower, than the light transmission value in thecontinuous land region 194.

TABLE 3 Light Transmission Value Delta (Feature Feature Land Area MinusDiscrete Std Std Land) Samples Feature Mean Dev Mean Dev Mean Example 4Depression 65.5 8.7 56.5 7.2 9.0 HUGGIES ® Tuft 51.9 5.5 59.3 7.9 −7.4Apertured topsheet Aperture 97.8 0.16 60.8 9.0 37.0

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “90°” is intended to mean“about 90°”.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method of forming deformations in a nonwovenweb, said method comprising the steps of: a) providing a precursornonwoven web, said precursor web comprising a nonwoven materialcomprising fibers, said precursor web having a first surface, a secondsurface, and a thickness; b) providing a pair of forming members havinga machine direction orientation and a cross-machine directionorientation, said forming members comprising: a first forming memberhaving a surface comprising a plurality of discrete, spaced apart maleforming elements having a base that is joined to the surface of saidfirst forming member, a top that is spaced away from said base, andsides that extend between the base and the top of said male formingelements, wherein said male elements have a plan view periphery, and aheight; and a second forming member having a surface comprising aplurality of recesses in said second forming member, wherein saidrecesses are aligned and configured to receive said male formingelements therein, wherein said recesses have a plan view periphery thatis larger than, and completely surrounds, the plan view periphery ofsaid male elements, and said recesses have a depth; and c) placing saidprecursor nonwoven web between said forming members, wherein the secondsurface of said precursor nonwoven web is placed in contact with saidfirst forming member, and mechanically deforming said precursor nonwovenweb with said forming members, wherein the precursor nonwoven web isformed into a nonwoven web comprising a generally planar first regionand a plurality of discrete integral second regions that comprisedeformations, said deformations forming protrusions extending outwardfrom the first surface of said nonwoven web, and openings formed in thesecond surface of the nonwoven web, said protrusions being comprised ofsaid fibers, wherein said protrusions comprise a base proximate thefirst surface of said nonwoven web, an opposed distal end extendingoutward in the Z-direction from the base, side walls between said baseand said distal end of said protrusion, and a cap comprising at least aportion of the side walls and the distal end of the protrusions, whereinsaid side walls have interior surfaces, wherein the interior surfaces ofthe side walls define a base opening at the base of the protrusion,wherein said cap has a portion with a maximum interior width, and thebase opening has a width, wherein the maximum interior width of the capof the protrusions is greater than the width of the base opening.
 2. Themethod of claim 1 wherein the sides of said male forming elementsintersect with the top of said male forming elements at a non-radiusededge.
 3. The method of claim 1 wherein at least one of said maleelements and said second forming member have at least two discretesurface texture elements thereon.
 4. The method of claim 3 wherein themale forming elements are not heated.
 5. The method of claim 1 whereinthe depth of said recesses is greater than the height of said maleforming elements.
 6. The method of claim 1 wherein the recesses in saidsecond forming member have substantially the same, but larger plan viewconfiguration than the plan view configuration of the male formingelements.
 7. The method of claim 5 wherein the Depth of Engagementranges from at least about 1.5 mm to about 5 mm.
 8. The method of claim5 wherein the clearance ranges from about 0.13 mm to about 1.3 mm. 9.The method of claim 1 wherein said precursor nonwoven web comprises twoor more layers of nonwoven material, each of which is comprised offibers.
 10. The method of claim 9 wherein said step (c) nests the layerstogether in a protrusion.
 11. The method of claim 1 wherein said step(c) forms bulbous protrusions in the web.
 12. The method of claim 9wherein said step (c) thins at least a portion of the fibers in at leastone of the layers.
 13. The method of claim 1 further comprising a step(d) of bonding at least a portion of the fibers together in the distalends of at least some of the protrusions.
 14. The method of claim 1further comprising a step (d) of bonding at least a portion of thefibers together in the first region of said nonwoven web outside thebase of at least some of the protrusions.